Chevrolet - Silverado 1500 4wd V8 - Workshop Manual - 2009 - 2009

Page 13165 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Locations Power Door Lock Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 7796 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 567 Page 12159 Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 17640 Page 15400 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Page 5242 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 9288 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Page 20550 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 3114 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure Page 14437 3. Install the steering shaft coupling bolt at the steering gear. Tighten the bolt to 47 Nm (35 lb ft). 4. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Remove anti-rotation pinJ 42640 from the steering column lower access hole. Page 17596 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Page 9665 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 8676 Seals and Gaskets: By Symptom Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. Page 12808 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 19568 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10105 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 11577 2. Raise and suitably support the vehicle. 3. Position the negative battery cable lead (3) behind the engine wiring harness ground lead (2). 4. Place the engine wiring harness ground lead (2) and the negative battery cable lead (3) to the frame. 5. Insert the anti-rotation tab on the engine harness ground lead into the hole in the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the engine wiring harness ground lead to the frame bolt (1) and tighten to 9 Nm (80 lb in) . 7. Lower the vehicle. 8. Position the engine wiring harness ground lead (2) behind the negative battery cable lead (3). 9. Place the negative battery cable lead (3) and the engine wiring harness ground lead (2) against the engine block boss. 10. Install the negative battery cable ground terminal to the engine block boss bolt (1) and tighten to 50 Nm (37 lb ft) . Page 5205 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 4278 6. Remove the spark plug wires from the spark plugs. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 7. Remove the spark plug wires from the ignition coils. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 8. Mark the relationship of the upper intermediate steering shaft to the steering column. 9. Remove the steering shaft coupling bolt (2) and nut (1) from the upper intermediate steering shaft. 10. Separate the upper intermediate steering shaft (3) from the steering column, position both shafts out of the way. Page 6318 CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft, through the 4X signal of the CMP sensor. If the difference between the actual and the desired position is greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Page 975 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 6767 Tighten the bolt to 9 Nm (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. If equipped with 2WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle. 10. Install the fuel/EVAP line bracket locator tab to the frame. 11. Install the fuel/EVAP line clips to the frame and crossmember. 12. Install the fuel/EVAP line bracket bolt (2). Tighten the bolt to 9 Nm (80 lb in). 13. Install the fuel/EVAP line clip nut (1). Tighten the bolt to 20 Nm (15 lb ft). 14. Remove the caps from the fuel and EVAP lines. 15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 11626 Charging System: Technical Service Bulletins Charging System - Low Voltage Display/Battery Discharged INFORMATION Bulletin No.: 02-06-03-008D Date: July 21, 2008 Subject: Low Voltage Display on IP Gauge, Lights Dim at Stop Lights, Battery Discharged, No Start, Slow Cranking, Dim Lights at Idle, Low Generator Output Models: 1990-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 02-06-03-008C (Section 06 - Engine). Any vehicle may have a low voltage display (if equipped with gauges), lights that dim at stop lights, slow cranking, no start, low generator output at idle or dim lights at idle when electrical loads are heavy at idle or under slow driving or infrequent usage conditions. These characteristics may be more noticeable with customer added electrical accessories, or with a discharged battery. These are normal operating characteristics of a vehicle electrical system and no repairs should be attempted unless a proven fault has been diagnosed. During normal driving conditions, when engine speed is above 1000 RPM, the generator is designed to do two things: ^ Supply the current necessary to operate the vehicle's originally equipped electrical devices (loads). ^ Recharge/maintain the battery's state of charge. The following factors may affect generator and battery performance: ^ Non-usage of the vehicle for extended periods of time. The vehicle's computers, clocks and the like will cause the battery state of charge to drop (For example; 30 days in a parking lot and the vehicle may not start because of a dead battery or a vehicle which is driven only a short distance once a week may end up with a discharged battery to the point where the vehicle may not start). This would be considered abnormal usage of the vehicle and the normally expected result for the vehicle battery, generator and electrical systems. ^ At idle, vehicle electrical loads may exceed the low speed current (amperage) output of the generator and when this happens the shortfall comes from the battery. This will result in a drop in the electrical system voltage as the battery delivers the additional electrical current to meet the demand. This is equivalent to the brown outs experienced by homes and businesses when the electrical demand is more than the supply. See Figure 1. ^ Extended periods of engine idling, with high electrical loads, may result in a discharged battery. Attempting to recharge a battery by letting the engine run at idle may not be beneficial unless all electrical loads are turned "OFF". Page 2987 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5406 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair) . 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair) . 3. Ensure that the sunroof does not have any air or waterleaks. Page 13930 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 14064 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Page 15379 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 9700 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 832 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 4869 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 20650 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Page 5897 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). 3. If equipped with 4WD perform the following steps, if equipped with 2WD proceed to step 6. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Install the CPA retainer (2). 6. Connect the HO2S electrical connector (3) to the engine wiring harness electrical connector (5). 7. Install the CPA retainer (2). 8. Lower the vehicle. Steering/Suspension - Power Steering Fluid Leaking Steering Rack Gear: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 18498 Seat Adjuster Motor Assembly - Passenger (AG2) Page 13749 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (A48) Page 18308 1. Position the sunroof motor/actuator (3) to the sunroof module. 2. Push the sunroof motor/actuator straight upward to engage the drive gear between the cables housed within the sunroof cable drive tubes. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sunroof motor/actuator screws (2) to the sunroof actuator. Tighten the screws to 4 Nm (35 lb in). 4. Connect the electrical connector (1) to the sunroof motor/actuator . 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 6. Initialize/teach the sunroof motor/actuator . Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Programming and Relearning) . 7. Inspect the sunroof for proper operation. 8. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and setup information. Page 1436 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Top of the Headliner Components (Regular Cab) Page 10588 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1182 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Page 2626 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 6641 Fuel Injector 4 (4.3L) Fuel Injector 4 (4.8L/5.3L/6.0L/6.2L) Page 5141 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 13198 Fuse Block - Underhood X4 Manual Shift Shaft Seal Replacement Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Page 15046 Compressor Clutch: Adjustments Air Conditioning Clutch Drive Plate Adjustment 1. Install the clutch plate assembly. Note Ensure the drive plate does not drag against the pulley when the pulley is rotated. 2. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the clutch plate retaining bolt and tighten to 18 Nm (13 lb ft) . Page 5404 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 13580 Page 6790 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 3552 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 13355 Junction Block - Left I/P X12 (except MEX) Page 15349 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 2972 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 4928 Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13486 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 19625 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Lighting - Exterior Lamp Condensation and Replacement Turn Signal Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 10203 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 8 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Page 20665 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 20217 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 17344 Front Door Panel: Service and Repair Upper Extension Trim Panel Replacement Upper Extension Trim Panel Replacement Page 651 Body Control Module (BCM) X6 Page 3086 Page 7826 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20654 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 17901 Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Page 2646 Fuse Block - Underhood X4 Page 12781 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse Block/Diagrams/Connector Views) to locate the electrical center where the relay exists. Note * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 20059 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 4279 11. Remove the exhaust manifold bolts, and exhaust manifold. 12. Remove and discard the exhaust manifold gasket. 13. Remove and discard the catalytic converter seal. 14. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold. Installation Procedure Note * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostic (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. * Do not apply sealant to the first 3 threads of the bolt. Page 4914 Page 3458 1. Oil enters the camshaft at the second main bearing journal (1). 2. Oil travels through the camshaft into the CMP actuator valve check ball (2) and filter (3). 3. Oil exits the valve and travels through the internal passages of the camshaft (4). 4. Oil exits the camshaft and enters the actuator oil entry ports. 5. Oil travels through the actuator and is directed back into the valve (5). 6. Valve spool position directs oil to the advance or retard passages of the actuator. The valve may also, under certain conditions, be positioned in a neutral position with no flow to either the advance or retard passages of the actuator. 1. Oil flows from the camshaft into the valve inlet (3) through the internal check ball and filter. 2. Oil exits the valve (2) and travels within the internal passages of the camshaft into the entry ports (7) of the actuator. 3. The center oil groove of the actuator is pressurized and oil reenters the valve (1). 4. Valve spool position directs oil out of the valve advance (4) or retard (5) ports to the actuator. The valve may also, under certain conditions, be positioned in a neutral position with no flow to either the advance or retard passages of the actuator. Specifications Refrigerant Oil: Specifications Refrigerant Oil Type Polyolester (POE) Oil GM P/N 88862657 (GM P/N 88862658 Canada) Page 12995 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13598 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 713 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 14537 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Page 6421 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12103 Junction Block - Left I/P X1 (except MEX) Page 20844 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 1450 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 12757 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 8445 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 16969 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 7184 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 11331 3. Clean any dirt and debris from the brake modulator assembly and the HPA. Note To ensure brake modulator and HPA pressure relief has occurred, the manual pressure relief valve must be opened momentarily. 4. Loosen the manual pressure relief valve (1) 1/4 turn counterclockwise. 5. Seat, but do not tighten, the manual pressure relief valve. Note Adequately support the brake modulator assembly to avoid placing stress on the brake pipes and hoses. 6. Without disconnecting the brake pipes and hoses, remove the brake pressure modulator assembly bracket. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly Antilock Brakes/Service and Repair) . 7. Remove the HPA (1). Page 12365 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 7790 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2583 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 17856 Glove Compartment: Service and Repair Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Page 4683 15. Install the HV dc battery cable (6) with seal (7) into the PIM distribution box. 16. Install the HV dc battery cable mounting fasteners (5). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 17. Install the high voltage (HV) dc battery cable terminal fasteners (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 18. Install the HV dc electric air conditioning compressor module (ACCM) cable (4) with seal (7) into the PIM distribution box. 19. Install the HV dc electric ACCM cable mounting fasteners (3). Tighten the mounting fasteners to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 20. Install the HV dc electric ACCM cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . 21. Install a new seal (3) on the PIM distribution box. Page 4656 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 4878 Page 12253 Junction Block - Rear Lamps X3 Page 1660 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 15232 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 92 Vehicle Communication Interface Module (VCIM) X3 (UE1 with U3U/UVB) Page 7178 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 7660 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 2816 Fuse Block - Underhood X6 Page 15566 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 264 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3218 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 12638 X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X224 Page 19736 Disclaimer Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 2882 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 5830 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 12372 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 16444 Television / Monitor: Service and Repair Video Display Replacement (Second Row) Page 15577 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Special Tools J 42640 Steering Column Anti-rotation Pin Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Verify the following before removing the inflatable restraint steering wheel module coil: * The wheels on the vehicle are straight ahead. * That anti-rotation pinJ 42640 is installed or the ignition and start switch is in the LOCK position. 2. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement) . 3. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 4. Disconnect any electrical connectors as needed. 5. Remove the inflatable restraint steering wheel module coil retaining ring (2) and discard it. DO NOT reuse the ring. 6. Remove the inflatable restraint steering wheel module coil (1) from the steering shaft. 7. If replacing, discard the old inflatable restraint steering wheel module coil. Installation Procedure Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Page 17854 Glove Compartment: Service and Repair Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Page 13305 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 6484 8. Remove the fuel pipe bracket nut from the bellhousing stud. 9. Remove the fuel line clip (1) from the bracket on the automatic transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 2419 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 531 Page 7749 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 8995 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 16467 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 11117 Brake Master Cylinder: Removal and Replacement Brake Hose Replacement - Intermediate Brake Master Cylinder Reservoir Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Note During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the brake fluid from the brake master cylinder reservoir until the level is below the reservoir supply hose fitting and discard into an approved container. 4. Disconnect the brake fluid level sensor electrical connector. 5. Disconnect the brake master cylinder reservoir return hose quick connect (1). 6. Disconnect the brake master cylinder reservoir supply hose quick connect (2). 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . Page 7107 Harness Components Page 3617 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 3902 1. Install NEW fuel injector lower O-ring seals onto the injectors. 2. Lubricate the NEW O-ring seals with clean engine oil. Note Push down firmly on both sides of the rail until all the injectors have been seated into their bores. 3. Install the fuel rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 5. Install a NEW throttle body gasket to the intake manifold. 6. Install the throttle body. 7. Install the throttle body bolts/nuts. Page 3363 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Locations Battery Bus Cover: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 12738 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Console Harness (Y91/UQA/D07) Page 10314 Harness Components Page 8888 Page 11661 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7893 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 3060 Page 8315 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 2558 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations . 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Page 3925 35. Connect the engine harness electrical connectors (7) to the right side fuel injectors. 36. Install the engine harness clip (6) to the ignition coil bracket stud. 37. Install the engine harness clip (4) to the generator battery jumper cable. 38. Connect the engine harness electrical connector (3) to the throttle actuator. 39. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 40. Install the CPA retainer (2). 41. Install the engine harness clip (4) to the ignition coil bracket stud. 42. Connect the engine harness electrical connectors (3) to the left side fuel injectors. 43. Connect the engine harness electrical connector (1) to the ignition coil harness electrical connector. 44. Install the CPA retainer (1). Page 1188 1 - Door Frame 2 - Door Lock Switch -Driver (AU3) 3 - Speaker -Left Front 4 - Door Latch -Driver Driver Door Components (AN3/DL3) Page 5726 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 6818 15. If equipped with 6 ft 5 in. bed, perform the following steps: 16. Disconnect the fuel tank EVAP line quick connect fitting (1) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 17. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 18. Remove the fuel tank fill pipe. 19. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. If equipped with 6 ft 5 in. bed, perform the following steps: 2. Remove the cap from the opening on the fuel tank. 3. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). Page 6410 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 5570 Rear Seat Belt Retractor Replacement (Crew Cab) Seat Belt Retractor: Service and Repair Rear Seat Belt Retractor Replacement (Crew Cab) Rear Seat Belt Retractor Replacement (Crew Cab) Page 9117 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 6092 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 14327 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 2809 Page 15092 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 15541 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 19480 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 20653 Door Lock/Window Switch - Passenger X4 (AN3) Page 6454 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Front of Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Front of Tank) Removal Procedure Note Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2). 3. Pull back on the retaining tab (1) and release the vent solenoid valve (2). A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 14073 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection ( See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Page 9436 Note If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 12. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level Inspection (9.25 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Front Drive Axle) . 13. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 14. Install the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 15. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 17. Lower the vehicle. Page 7206 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Interior - Lint Accumulation On Ebony Colored Seats Arm Rest: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 4726 Page 16738 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 8226 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 9576 Note Ensure that the reference marks are aligned before installing the propeller shaft. 4. Align the reference marks on the propeller shaft (1), universal bearing cap (4), pinion flange (5), and the rear axle housing (6). 5. With the reference marks aligned, install the propeller shaft (1) on the rear axle (6). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the rear propeller shaft bolts (3) and the strap (2). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Remove the support and lower the vehicle. Page 13192 Page 13798 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Page 19520 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7621 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 17889 Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Regular Cab) Page 20340 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Locations Acceleration/Deceleration Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 13303 Fuse Block - I/P X4 Page 9442 Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer Removal Procedure Note The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Note In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 4. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 5. Remove the axle nut retaining ring. Page 7353 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 12331 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11416 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 14495 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 12616 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Page 2688 Fuse Block - Underhood X4 Page 14731 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 7442 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 15089 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 10790 44. If the primary brake pipe port (1) was not fully bled within the 60-second cycle time, press Start to repeat Steps 42-43. 45. Press Enter to continue. 46. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 47. Open the right rear (RR) brake caliper bleeder valve. Ensure the RR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 48. If the RR bleeder valve was not fully bled within the 60 second cycle time, press Start to repeat Step 47 until the brake fluid is clear of any air. 49. Press Enter to continue. 50. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 51. Open the left rear (LR) brake caliper bleeder valve. Ensure the LR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 52. If the LR bleeder valve was not fully bled within the 60-second cycle time, press Start to repeat Step 51 until the brake fluid is clear of any air. 53. Press Enter to continue. 54. Secure bleeder hoses to all 4 brake caliper bleeder valves. 55. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 , in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 56. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 57. Press Enter to continue. 58. Remove the J 35589-A and the J-29532-A orJ 29532 from the vehicle. Note The system is active and pressurized, therefore the brake fluid level in the master cylinder reservoir cannot be allowed to be higher than the MAX mark of the operating range. 59. Ensure the master cylinder reservoir is filled no higher than the MAX operating range line. Add or remove brake fluid as necessary. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 60. Start the engine. 61. Press Start to continue the final sequence. The pump and the HPA circuits are being flushed, and the boost valve is being calibrated and learned by the EBCM through this step. 62. Continue to follow the instructions on the scan tool. 63. Allow the engine to idle for 1 minute to allow the system to recalibrate. 64. Turn the engine OFF, then turn the ignition switch to the ON position without starting the engine. 65. Clear any DTCs from the EBCM. 66. The hybrid brake control modulator is an OBDII compliant module. As such, brake related DTCs may be stored in the powertrain control modules. After addressing any other stored DTCs, clear any brake related DTCs stored in the powertrain control modules. 67. Turn the ignition switch to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 68. Allow the vehicle to remain OFF for at least 1 minute before applying the brake pedal, starting the engine, or performing a test drive. This waiting period is essential to complete the sensor and boost valve calibration and EBCM learn processes, and to allow the HPA to depressurize to allow for a deactivated system pedal feel check. 69. Remove the scan tool from the vehicle. 70. Before starting the engine, firmly apply the brake pedal several times. Observe the brake pedal feel. 71. If the brake pedal feels spongy, perform the following: 1. Repeat the base hydraulic brake system bleeding procedure. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . 2. If the brake pedal feel is now firm, repeat the automated bleeding procedure. 3. If the brake pedal stills feels spongy after repeating the base hydraulic brake system bleeding procedure, inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 72. If the brake pedal stills feels spongy, an if no external brake fluid leaks are found, inspect the brake system for internal leaks and inspect the brake pedal travel. Refer to Brake System Internal Leak Test (Two-mode Hybrid) (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System Internal Leak Test)Brake System Internal Leak Test (Non-Hybrid) (See: Hydraulic System/Testing and Page 9502 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Page 12839 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 733 Engine Control Module (ECM) X1 (Gas Except 4.3L/LY6/HP2) Page 3650 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair) . 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note Page 11076 Page 14729 Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 18487 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 3059 Junction Block - Right I/P X3 Page 10867 Brake Pad: Specifications Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. Page 978 Director, Customer and Relationship Services 09241 Page 6264 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 5794 Information Bus: Electrical Diagrams Data Communication Schematics Low Speed Bus - 1 of 3 Low Speed Bus - 2 of 3 Page 6974 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 19479 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 5135 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 4526 Drive Motor Generator Battery Control Module X4 (HP2) Page 15750 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Extended Cab) Seat Belt Replacement - Center Rear (Extended Cab) Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Page 10816 Page 6543 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 2684 Page 1710 Disclaimer Page 9093 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 13214 Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Fuse Holder X4 (Engine Chassis Harness) (Diesel) Page 13955 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 3673 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner (2) clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 13008 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 18069 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 13802 X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (NQF/NQH/HP2 Except Late Production with 4.8L/5.3L/6.0L/6.2L) Blower Motor Control Module Control Module HVAC: Diagrams Blower Motor Control Module Component Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 10559 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 2593 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 10229 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 1634 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 3492 7. Using a cutter type tool, cut the 8 retaining straps. 8. Remove the outer gasket (1) from the valve lifter oil manifold. Installation Procedure Note All gasket surfaces should be free of oil or other foreign material during assembly. Page 6036 Page 11690 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 33 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 3522 1. Install the a NEW CMP actuator solenoid valve until snug. With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the CMP actuator solenoid valve. 1. Tighten the solenoid valve a first pass to 65 Nm (48 lb ft). 2. Tighten the solenoid valve a final pass and additional 90 degrees using J 45059 . 3. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . Page 9811 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 271 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 2936 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 3915 35. Remove the upper intake manifold cover nut. 36. Remove the upper intake manifold cover. 37. Remove the manifold absolute pressure (MAP) sensor retainer. 38. Remove the MAP sensor. Page 12609 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Page 6900 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 11424 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 18667 Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Page 18747 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 6820 13. Position the fuel tank fill pipe ground wire to the frame bracket. 14. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole. 15. Install the fuel tank fill pipe ground wire bolt. Tighten the bolt to 9 Nm (80 lb in). 16. Lower the vehicle. 17. Install the fuel tank filler housing. 18. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 19. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Fuel Tank Filler Pipe Replacement Fuel Tank Filler Pipe Replacement Page 8140 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 15016 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 2925 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 12649 X300 Chassis Harness to Engine Harness (4.8L/5.3L/6.0L/6.2L) Page 19626 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 8752 Devices and Sensors Page 13516 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Retractor: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 535 Page 5812 Page 4563 Generator Control Module Temperature Sensor (HP2) Page 5209 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 15140 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement Sealing Washer Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Page 583 Power Vacuum Brake Booster Replacement (LY7) Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (LY7) Power Vacuum Brake Booster Replacement (Non-Adjustable Pedals) Page 13817 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 13218 Junction Block - Left I/P, Bottom View Page 7799 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 411 Electronic Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 18946 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 3571 6. Install the NEW crankshaft balancer bolt (139). 1. Tighten the bolt a first pass to 50 Nm (37 lb ft). 2. Tighten the bolt a final pass to 140 degrees using J 45059 . 7. Remove the J 42386-A (1) and bolts. 8. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2). 9. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (V8) (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement) . 10. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Powertrain Management/Computers and Control Systems/Crankshaft Position Sensor/Service and Repair) . Page 14308 Steering Control Module: Diagrams Component Connector End Views Electronic Power Steering Motor Control Module X1 (HP2) Electronic Power Steering Motor Control Module X3 (HP2) Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Page 13023 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 1521 Drive Motor Generator Battery Control Module X2 (HP2) Page 7620 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 6695 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 12974 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 18106 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Component Views Page 18779 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13402 Page 8125 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6112 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 4044 4. Tighten the air cleaner outlet duct clamp (1) at the MAF/IAT sensor. Tighten the clamps to 4 Nm (35 lb in). 5. Install the radiator inlet hose clamp clip (2) to the air cleaner outlet duct (1). 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . Page 14934 Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Page 20510 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5595 Engine Control Module (ECM) X1 (HP2) Page 13142 Page 12469 Fuse Block - Underhood Bottom View Page 9296 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 19224 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 14309 Electronic Power Steering Motor Control Module X4 (HP2) Page 18679 Page 9249 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Page 17442 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10634 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 9488 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair/Front Wheel Drive Shaft Seal Protector Replacement) . Note Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Page 13049 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 16728 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 17422 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 9789 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 9489 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart usingJ 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). Page 19185 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Page 873 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in) . Page 11453 1. Install the brake booster vacuum sensor grommet to the brake booster. 2. Install the brake booster vacuum sensor to the brake booster. 3. Connect the chassis wiring harness electrical connector (1) to the brake booster vacuum sensor. Page 4935 Page 15283 Control Module HVAC: Diagrams HVAC Control Module Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67/C42/MEX) Page 3886 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6956 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 1264 Power Seat Switch: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 15814 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14944 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 12559 For vehicles repaired under warranty, use the table. Disclaimer Page 6448 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 19058 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Page 6960 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 7209 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) Page 3003 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3346 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 8298 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 1519 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 6886 Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the fill plug and tighten to 33 Nm (24 lb ft) . 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 15529 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10286 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 20421 For vehicles repaired under warranty, use the table. Disclaimer Page 19392 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 5236 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 4900 Page 9089 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 12953 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 1471 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 14648 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 14893 Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Air Temperature Actuator (C67/C42) Page 19638 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 7717 Page 11904 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 14882 Page 15075 7. Install the lower bolts to the hood latch support bracket and tighten to 9 Nm (80 lb in) . 8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to Radiator Support Replacement () . Tighten the nut to 16 Nm (12 lb ft). 9. Install radiator support bracket bolts (1). 10. Install the fascia. 11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) ()Refrigerant Recovery and Recharging (HP2) () . 12. Leak test the fittings of the component using the J 39400-A . Page 14918 Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 12659 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 20655 Sliding Rear Window Close Relay (A48) Page 7722 Page 15574 Page 11028 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Page 2728 Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15586 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 17866 Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Page 20904 All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Daily Rental (Avis, Budget, Enterprise, etc.) Issue check to the daily rental company if valid proof of vehicle ownership documentation is available. Confirm local address and mail or provide check to their representative at vehicle pickup. All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Lease Management Company (PH&H;, GE Capital, ARI, etc.) Issue check to the lease management company if valid proof of ownership documentation is available. Ask the customer where the check should be mailed. Approximately 7,500 vehicles are involved and these customers will be receiving a letter from their lease management company explaining this situation. All checks must include the complete 17 character Vehicle Identification Number. Q12. What should I do if a customer refuses to have the recall service procedure performed on his/her vehicle? A12. If a customer initially declines the recall repair, please make sure that he/she fully understands the possible consequences. Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (HWFS). As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10153. - Schedule an appointment with your GM dealer/retailer. - This service will be performed for you at no charge. Why is your vehicle being recalled? A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. What will we do? Your GM dealer/retailer will permanently disable and remove the heated washer fluid system. In addition, because the heated washer feature will be disabled, the dealer will provide a customer satisfaction payment of $100 to the customer. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer/retailer will need your vehicle longer than the actual service correction time of approximately 20 minutes. An updated page for your Owner Manual will be provided and inserted at the time of service to document that the feature has been permanently disabled and removed from your vehicle. If your vehicle is within the New Vehicle Limited Warranty, your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? You should contact your GM dealer/retailer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition repaired in the past, you will still need to take your vehicle to your dealer/retailer for this recall. Page 16035 Page 9575 2. Align the reference marks on the propeller shaft (4), the slip yoke (2), the universal bearing caps (3), the transmission or the transfer case (1). 3. Install the propeller shaft in the transmission or transfer the case. Page 5073 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Page 15420 A/C Refrigerant Pressure Sensor (HP2) Page 5744 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7250 Module Circuit Function Icons Page 12387 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 15364 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Page 1046 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 5401 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 6851 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Page 12421 Fuse Block - Auxiliary X1 (HP2) Page 3627 Note Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . Page 11016 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Page 14979 Blower Motor: Diagrams Component Connector End Views Blower Motor Blower Motor Control Module X1 Page 9676 Director, Customer and Relationship Services 09241 Page 13317 Fuse Block - Underhood X2 Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Drivetrain - Clunk Noise At A Stop Or From Launch Slip Yoke: All Technical Service Bulletins Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 2921 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 144 Page 1086 Page 18064 Door Lock/Window Switch - Passenger X4 (AN3) Page 20124 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JD9, JF3, JF7) Page 5943 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 17313 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 18484 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 2183 Door Lock/Window Switch - Passenger X4 (AN3) Page 6819 5. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 6. If equipped with 5 ft 8 in. bed, perform the following steps: 7. Remove the cap from the opening on the fuel tank. 8. Position the fuel tank fill pipe. 9. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 10. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 12. Close the axle vent hose clip. Page 5044 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Page 9614 Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement Removal Procedure 1. Remove the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . Note Note the position and direction of the engine flywheel before removal. 2. Remove the flywheel bolts (1). 3. Remove the flywheel. Installation Procedure Note The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. Page 1072 Page 16705 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: All Technical Service Bulletins Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Page 12709 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Page 544 Page 6188 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 8503 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears through the 3 slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the 3 retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Page 11828 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 4635 23. Remove the sight shield circuit breaker fasteners (1). 24. Remove the sight shield circuit breaker (2). 25. Remove the APM ground strap fastener (2) and ground strap (1). 26. Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4). 27. Remove the ball studs (1) from the drive motor generator control module. 28. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 29. Lift the drive motor generator control module assembly from the vehicle. 30. To replace the drive motor generator power inverter module (PIM) assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation (See: Drive Motor Generator Power Inverter Module Removal and Installation) . To replace the accessory DC power control module, refer to Accessory DC Power Control Module Removal and Installation (See: Accessory DC Power Control Module Removal and Installation) . Installation Procedure Page 4888 Page 12994 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17859 Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Page 11022 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Page 4109 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 3278 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1399 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 18441 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 6215 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Page 5093 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 18491 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Page 13228 Junction Block - Left I/P X8 (except MEX) Page 18107 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 8779 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 13118 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8619 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 12182 Fuse Block - I/P Top View Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 11109 Caution: Refer to Fastener Caution. 9. Install the brake pipe manifold bolts (1) and tighten to 11 Nm (97 lb in) . 10. Assemble 4 new O-ring seals to the master cylinder return hose fitting (1) and the master cylinder supply hose fitting (2). 11. Lubricate the new O-ring seals with GM approved brake fluid from a clean, sealed brake fluid container. 12. Install the return and supply hose fittings to the brake modulator valve assembly and tighten to 8 Nm (71 lb in) 13. Install the brake modulator assembly. Refer to Brake Pressure Modulator Valve Replacement. Page 8300 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 16045 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series Except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series Except Crew Cab/MEX) Page 11758 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 12058 Fuse Block - Auxiliary (HP2), Bottom View Page 18855 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Hybrid Controls Electronic Component Views Drive Motor Power Cable: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 19601 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 10939 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools J-45101-100 - Conical Brake Rotor Washers Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J-45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement) . 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer toBrake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) . 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - washers and the lug nuts. Page 5211 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Powertrain Component Views Left Side of the Engine Components (Diesel) Page 13757 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Page 13544 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 19204 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6330 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . 2. Remove and discard the CMP actuator solenoid valve. Installation Procedure Page 19631 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 12364 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 18146 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 13298 Fuse Block - I/P Top View Page 5676 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 5870 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 19544 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 712 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 12958 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12101 Junction Block - Left I/P, Top View Page 20176 Page 7219 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13193 Fuse Block - Underhood X2 Page 6022 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 7195 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 20013 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 13380 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Page 6271 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2733 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 11328 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J-26889 Compressor . 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure Page 18750 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 14142 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 10469 24 - Transfer Case Oil Fill Plug 25 - Transfer Case Oil Drain Plug 26 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 27 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 28 - Transfer Case Shift Detent Plunger Plug 29 - Transfer Case Shift Detent Plunger Plug - O-Ring - Seal 30 - Transfer Case Shift Detent Spring 31 - Transfer Case Shift Detent Plunger Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 - Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Insert 12 - Transfer Case Shift Fork Spring Page 765 Page 13528 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2681 Fuse Block - Underhood X1 Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (4.3L) Tire Monitor System - Tire Pressure Light Stays ON Door Module: All Technical Service Bulletins Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Page 2638 Fuse Block - Underhood Bottom View TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 4285 10. Remove and discard the exhaust manifold gasket. 11. Remove and discard the exhaust manifold seal. 12. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold. Installation Procedure Note * Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. * The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. * Do not apply sealant to the first 3 threads of the bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Page 6573 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 2957 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10895 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Page 17401 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Air Bag Deactivation Indicator: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 968 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 9410 Note DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Page 9864 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 20943 Page 12041 Page 6110 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 11697 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5144 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 11397 Electronic Brake Control Module (EBCM) (JF3/JF7) Page 19111 Air Dam: Service and Repair Front Air Deflector Replacement (Chevrolet) Front Air Deflector Replacement (Chevrolet) Page 13360 Page 20657 Sliding Rear Window Switch (A48) Window Switch - Driver X1 (A31 without AN3/DL3) Page 20366 Page 8093 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (5.3L/6.0L Except LY6) Page 7117 Page 18752 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 16913 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 3641 Note * All gasket surfaces should be free of oil or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * If the oil fill tube has been removed from the rocker arm cover, install a NEW fill tube during assembly. 1. Lubricate the O-ring seal (422) of the NEW oil fill tube with clean engine oil. 2. Insert the NEW oil fill tube (423) into the rocker arm cover. Rotate the tube clockwise until locked in the proper position. 3. Install the oil fill cap (424) into the tube. Rotate the cap clockwise until locked in the proper position. 4. Install a NEW rocker cover gasket (1) into the valve rocker arm cover lip. Page 1947 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 2880 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components Page 13237 Page 8489 8. Connect the transmission wiring harness to the control solenoid valve body (3). 9. Install the transmission wiring harness connector (1) to the wire harness retainer. 10. Install the transmission wiring harness to the wire harness retainer (2). 11. Install the transmission electrical connector passage sleeve. Refer to Automatic Transmission Electrical Connector Passage Sleeve Replacement ( See: Wiring Harness/Service and Repair/Automatic Transmission Electrical Connector Passage Sleeve Replacement) . 12. Install the transmission fluid filter and auxiliary fluid pump filter. Refer to Automatic Transmission Fluid Filter and Auxiliary Fluid Pump Filter Replacement (See: Service and Repair/Removal and Replacement) . 13. Lower the vehicle. Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 9763 Disclaimer OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 2924 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11285 11. Install the front park brake cable to the frame and press the retainer into place. 12. Connect the front park brake cable to the front to intermediate park brake cable connector. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Enabling) . 15. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Page 8547 Fluid Pump: Service and Repair Auxiliary Fluid Pump and Gasket Replacement Auxiliary Fluid Pump and Gasket Replacement Removal Procedure 1. Disconnect the auxiliary fluid pump wire harness (1) from the auxiliary fluid pump control module connector (2). 2. Remove the auxiliary fluid pump wire harness (6) from the harness retainers (7). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Remove the auxiliary fluid pump wire harness clip nut (3). 5. Place a suitable drain pan under the transmission auxiliary fluid pump. 6. Remove the auxiliary fluid pump bolts (1). Caution: Do not damage the case sealing surface when removing or installing the pump and motor assembly. Page 15099 Locations Power Window Relay: Locations Passenger Compartment/Roof Component Views Rear of the Passenger Compartment Components 1 - Information Center Telltale Assembly (UD7) 2 - Sliding Rear Window Open Relay (A48) 3 Sliding Rear Window Close Relay (A48) 4 - Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) 5 - Sliding Rear Window Motor (A48) Page 10467 23 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Inner 24 - Transfer Case Front Output Shaft Drive Chain Assembly 25 - Transfer Case Front Output Shaft Drive Sprocket 26 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 27 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 28 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 29 - Transfer Case Oil Pump Assembly 30 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 31 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 32 Transfer Case Rear Output Shaft Rear Bearing Assembly 33 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 34 - Transfer Case Oil Pump Suction Pipe 35 - Transfer Case Oil Pump Suction Pipe Seal 36 - Transfer Case Front Output Shaft Driven Sprocket Spacer Spring 37 Transfer Case Front Output Shaft Driven Sprocket Spacer 38 - Transfer Case Front Output Shaft Driven Sprocket 39 - Transfer Case Front Output Shaft Hole Plug 40 - Transfer Case Front Output Shaft 41 - Transfer Case Front Output Shaft Front Bearing Assembly Page 16078 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 13392 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 2674 Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 10720 Page 12979 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 1664 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 14426 Page 4660 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 12603 Page 3244 Disclaimer Page 12093 Fuse Block - I/P X3 Page 20296 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 13167 Fuse Block - I/P X2 (except MEX) Page 7960 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Locations Coolant Level Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Page 13526 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Locations Battery Cooling Duct: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 3043 Junction Block - Left I/P X3 (except MEX) Page 19903 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Page 1508 Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 9290 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Page 2299 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 2966 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 8306 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 20389 Page 12435 Junction Block - Left I/P X2 (except MEX) Page 8367 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 19278 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . Page 3906 22. Position and install the PCV hose to the intake manifold fitting. 23. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 24. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 11738 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 11101 21. Install the ABS module splash shield retainer (1). 22. If installing a new EBCM, the EBCM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . 23. Perform theAntilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair) . Follow the procedure completely to ensure the sensor and boost valve calibration and EBCM learn processes have been completed. Page 8993 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 13620 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 11420 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 14041 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 5847 Page 8201 Page 6378 3. Disconnect the engine wiring harness electrical connector (2) from the EVAP canister purge solenoid. 4. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 6. Remove the EVAP canister purge solenoid. Installation Procedure 1. Install the EVAP canister purge solenoid. 2. Install the EVAP canister purge solenoid to the fuel rail and engage the retainer. Page 12687 Page 9861 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 17251 Parts Information Disclaimer Page 2551 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 12419 Fuse Block - Auxiliary (HP2), Top View Page 13354 Junction Block - Left I/P X11 (except MEX) Page 11670 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 2874 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 9675 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 18528 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Page 12969 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Hood Open Assist Spring Replacement Hood Shock / Support: Service and Repair Hood Open Assist Spring Replacement Hood Open Assist Spring Replacement Page 7802 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13480 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 14999 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Hood Primary Latch Release Cable Handle Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Page 13931 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 5781 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 19477 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6041 Engine Control Module (ECM) X1 (LY6) Page 19343 Disclaimer Page 2794 Page 13852 X300 Chassis Harness to Engine Harness (4.8L/5.3L/6.0L/6.2L) Service and Repair Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement) . 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution) . 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. Page 5597 Engine Control Module (ECM) X1 (LY6) Page 11735 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Page 19138 11. Reinstall the foam (1) to the latch rod. 12. Reinstall the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 13. Reinstall the right endgate latch. Refer to Endgate Latch Replacement in SI. 14. Reinstall the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13801 Page 2657 Fuse Block - I/P X2 (except MEX) Page 9079 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 10079 Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 11852 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 12097 HEADLINER 3 ..................................................................................................................................... ........................... Headliner Harness Connector 3 HEADLINER 2 ...................................................... .......................................................................................................... Headliner Harness Connector 2 HEADLINER 1 ..................................................................................................................................... ........................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Page 13376 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Fuse Block Jumper Harness Routing (9L4) Page 1749 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 853 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab with 10 Series with ASF) Page 19150 6. Using a suitable tool, at the center of the rod, bend one leg of the rod towards the center as shown (1). The object is to make one end of the "U" shaped section of the rod close to a 90 degree bend. Take care not the twist the rod as you bend it. 7. Using the same tool, straighten the rod at the other bend shown (1) until the rod is back straight. Take care not to twist the rod as you bend it. 8. Inspect the rod standing up on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 9. Inspect the rod laying flat on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 10. Inspect the overall length of the rod as shown. The overall length of the rod should be 3-4 mm (0.118-0.157 in) shorter. If the length is not correct, rebend the rod using the steps above to achieve the correct length. Page 19521 Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 7884 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 9460 Axle Bearing: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer Removal Procedure Note The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Note In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 4. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 5. Remove the axle nut retaining ring. 6. Remove the key. Page 2914 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 12070 Page 10620 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5868 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10658 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 17042 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Page 13816 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Page 7373 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 16054 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Page 13841 X214 Inline Harness Connector End Views Page 15877 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 2376 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Locations Ignition Coil: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 12313 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15803 Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Ext Cab w/AM7) Rear Seat Center Belt Buckle Replacement (Ext Cab w/AM7) Page 18847 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 4470 Drive Motor Generator Battery Control Module X2 (HP2) Page 7271 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 8680 Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. Page 8382 Disclaimer Page 15003 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 10682 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 3047 Junction Block - Left I/P X8 (except MEX) Page 4561 Generator Battery Vent Fan Relay (HP2) Page 164 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10416 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 848 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 Page 11822 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 5708 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3389 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Page 12580 Multiple Junction Connector: Connector Locations Harness Routing Views Driver Door Harness Routing 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Passenger Door Harness Routing Page 12666 X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 5849 Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 6121 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 13196 Fuse Block - Underhood X3 Page 12764 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 7267 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 20427 Locations Seat Belt Tensioner: Locations Passenger Compartment/Roof Component Views Left Side of the Passenger Compartment Components (Extended/Crew Cab) 1 - Inflatable Restraint Roof Rail Module - Driver (ASF 2 - Rear Window Defogger Grid (C49) 3 Seat Belt Pretensioner - Driver Right Side of the Passenger Compartment Components (Extended/Crew Cab) Page 15674 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10813 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Page 3917 45. Remove the fuel rail bolts. Note Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 46. Remove the fuel rail. 47. Remove and discard the fuel injector lower O-ring seals. Note Evenly push in the RED collar in order to remove the nipple. 48. Remove the brake booster vacuum hose nipple. Installation Procedure Page 14436 6. Remove the steering shaft coupling nut (1) and bolt (2) at the upper intermediate steering shaft. 7. Remove the steering shaft coupling from the vehicle. Installation Procedure Note If a new steering shaft coupling is being installed then transfer the position of the alignment marks from the old component to the same locations on the new component. Failure to transfer the alignment marks may result in an off-center steering wheel after installation. 1. Install the steering shaft coupling to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the steering shaft coupling nut (1) and bolt (2) at the upper intermediate steering shaft. Tighten the nut and bolt to 50 Nm (37 lb ft). Page 2130 Steering Linkage Inner Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement Steering Linkage Inner Tie Rod Replacement (Two Mode Hybrid) Special Tools CH-49009 Inner Tie Rod Wrench Removal Procedure Note After removing the steering gear boot, inspect the steering linkage inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. Note The appropriate flats on the steering gear rack are only present on the driver side of the vehicle. If the passenger side steering linkage inner tie rod must be replaced then the steering gear boot must be removed from the driver's side as well in order to hold the steering gear rack from rotating. Replacing the passenger side steering linkage inner tie rod will require two people, one to hold the steering gear rack and one to install the steering linkage inner tie rod. 1. Remove the steering gear boot. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair) . 2. Disengage the steering linkage inner tie rod washer (1) from the steering linkage inner tie rod. Page 10409 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 5421 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Page 7371 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 11065 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). Page 5718 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Page 7060 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Page 9032 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 7326 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 15341 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2/C67) Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3033 Page 10565 Page 7972 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 13201 Page 1191 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 17614 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 5071 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 13846 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Page 3725 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12844 Disclaimer Page 15508 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 13463 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 7106 Module Circuit Function Icons Page 2738 Junction Block - Rear Lamps X1 Page 11832 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics) . Page 13215 Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Instrument Panel Fuse Block INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. Page 20261 Page 20581 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Page 1970 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended/Crew Cab with ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Page 7495 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 14357 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 11813 Page 115 Disclaimer Page 1966 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Under the Front Seats Components Page 7274 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 18834 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Front Side Door Pull Handle Replacement Front Door Panel: Service and Repair Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 18526 Power Seat Switch: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 7015 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 6993 Page 16706 Speaker - Right Front Tweeter (Except MEX) Speaker - Right Rear (Extended Cab/Crew Cab with UQ3/UQ5) Page 16828 Page 7325 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 8248 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1494 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 10034 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 18259 Seat Climate Control Module X1 (KB6) Page 13387 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Right Side of the I/P Components Page 10722 4. Remove the ABS module splash shield bolts (1). 5. Remove the ABS module splash shield (1). Page 19922 Disclaimer Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 5770 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 3026 Fuse Block - Auxiliary (HP2), Bottom View Page 20500 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 8050 Component Parts Page 16214 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 18529 Seat Adjuster Switch - Passenger (AG2 without AN3) Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 1083 Page 18600 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 12379 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 18010 Page 2539 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 7149 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 17224 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 18815 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 10793 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent . Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter . 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 19485 * The cruise control On/Off switch * The cruise control cancel switch The body control module (BCM) determines when the cruise control cancel switch is activated. When the normally open cancel switch is closed, the BCM detects the predetermined voltage signal on the cruise control function switch circuit. The BCM sends a GMLAN serial data message to the ECM in order to disengage the cruise control system. The stop lamp switch is mounted on the brake pedal bracket. When the brake pedal is applied, the normally open stop lamp switch closes. The ECM monitors the stop lamp signal circuit through a discrete input and a GMLAN serial data message signal from the BCM indicating the brake status. When both signals indicate the brake pedal is applied, the ECM will disengage the cruise control system. The Cruise Control System will disengage when the cruise control on/off switch is switched OFF. The vehicle speed stored in the memory of the engine control module will be erased when the cruise control On/Off switch is turned OFF, or the ignition switch is turned OFF. The Cruise Control System will disengage when the ECM detects that a driver override function has been active for approximately 60 seconds. When the Cruise Control System has been disengaged, the ECM sends a GMLAN serial message to the instrument panel cluster (IPC) in order to turn OFF the Cruise Engaged indicator, and to the driver information center (DIC) in order to turn OFF the CRUISE SET TO ### message. Each time the Cruise Control System is disengaged, the ECM will keep track of the reason for system disengagement. The last 8 disengagement reasons will be recorded within the ECM memory, and can be viewed with a scan tool. Cruise Control Inhibited The engine control module (ECM) inhibits the cruise control operation when any of the following conditions exist: * The ECM has not detected a brake pedal activation from the body control module (BCM). * A Cruise Control System DTC has been set. * The vehicle speed is less than 40.2 km/h (25 mph). * The vehicle speed is too high. * The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear. * The engine RPM is too low. * The engine RPM is too high. * The system voltage is not between 9-16 volts. * The Antilock Brake System (ABS)/Traction Control System (TCS) is active for more than 2 seconds. Page 12163 Fuse Block - Underhood X4 Page 2280 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 5713 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 7752 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 11768 * The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds. * The ignition is ON, with the engine OFF. Battery Voltage Gauge Operation The IPC displays the system voltage as received from the BCM over the GMLAN serial data circuit. If there is no communication with the BCM then the gauge will indicate minimum. This vehicle is equipped with a regulated voltage control (RVC) system. This will cause the voltmeter to fluctuate between 12 and 14 volts, as opposed to non-regulated systems which usually maintain a more consistent reading of 14 volts. This fluctuation with the RVC system is normal system operation and NO repairs should be attempted. SERVICE BATTERY CHARGING SYSTEM The BCM and the ECM will send a GMLAN message to the DIC for the SERVICE BATTERY CHARGING SYSTEM message to be displayed. It is displayed whenever the charge indicator is commanded ON due to a failure. Page 5684 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 13793 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Page 17115 Trailer Brake Control Module (JL1 with 31 Series) Page 6172 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 11283 10. Remove the park brake lever mounting nuts. 11. Position the floor carpet to expose the park brake cable pass-through grommet. 12. Release the park brake cable pass-through grommet from the vehicle floor. 13. Remove the park brake lever and front cable from the vehicle. Installation Procedure Note Ensure the grommet for the front park brake cable is properly seated in the front floor panel. 1. Insert the front brake cable through the hole in the front floor panel and seat the pass-through grommet. 2. Position the floor carpet to the floor pan. Page 3716 1. Lubricate the O-ring seal (421) with clean engine oil. 2. Install a NEW O-ring seal onto the oil level indicator tube, if required. 3. Install the oil level indicator tube (420) between the exhaust manifold and engine block. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Insert the oil level indicator tube into the block. The tube must be installed with the collar flush to the block. 6. Lower the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Install the oil level indicator tube bolt (419). Tighten the bolt to 25 Nm (18 lb ft). 8. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 9. Install the oil level indicator (418). Page 3310 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 8474 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 11792 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Park Pawl Cover and Gasket Replacement Parking Pawl: Service and Repair Park Pawl Cover and Gasket Replacement Park Pawl Cover and Gasket Replacement Page 20229 Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly Oil Cooler: All Technical Service Bulletins Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly TECHNICAL Bulletin No.: 08-06-02-003A Date: October 27, 2010 Subject: Engine Oil Leak at Engine Oil Cooler Hose/Pipe Adapter to Engine Connection (Diagnose and Repair as Outlined) Models: 2007-2011 Chevrolet Silverado, Suburban, Tahoe 2008-2011 Chevrolet Express 2007-2011 GMC Sierra, Yukon, Yukon XL 2008-2011 GMC Savana Equipped with 4.8L, 5.3L, 6.0L or 6.2L V8 Engine (VIN Code C, M, L, J, 4, 0, 3, 5, K, Y, 8 or 2 - RPO LY2, LH6, LY5, LMF, LMG, LC9, LFA, LY6, L76, L92 or L9H) and Engine Oil Cooling System RPO KC4 Supercede: This bulletin is being revised to clarify the Subject text, add model years, Cause, Correction, graphics and part number information. Please discard Corporate Bulletin Number 08-06-02-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak. Upon further investigation, the technician may find engine oil leaking from the engine oil cooler hose/pipe adapter at the point where it connects to the engine. Cause This condition may be caused by any of the following: - A damaged engine oil cooler hose/pipe adapter gasket, due to a temporary steel sealing device not being removed when the engine oil cooler hose/pipe adapter was first connected to the engine. - Previous oil leak servicing of the engine oil cooler hose/pipe adapter gasket that involved failing to remove the temporary steel sealing device. - Casting porosity at the engine oil cooler hose/pipe adapter bolt holes of the engine. - The engine oil cooler hose/pipe adapter bolts are not torqued to the proper specification. Correction 1. Perform the oil leak diagnosis procedure. Refer to Oil Leak Diagnosis in SI. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 3. The temporary steel sealing device (1) is shown separately from the adapter gasket (2). The temporary steel sealing device SHOULD NOT be installed on the engine or the engine oil cooler hose/pipe adapter. Note Page 11522 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 5234 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 3979 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 6. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. 7. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. 8. Remove the timing chain tension bolts (231) and tensioner (232). Page 13334 Fuse Block - Auxiliary X3 (HP2) Page 14549 Suspension Travel Bumper: Service and Repair Rear Suspension Spring Jounce Bumper Replacement (1500) Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12418 Fuse Block: Connector Views Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Fuse Block - Auxiliary Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 7287 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 15139 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 4782 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17216 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Steering Wheel Heater Control Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 5136 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 26 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 3329 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp clip (2) from the air cleaner outlet duct (1). OnStar(R) - Aftermarket Device Interference Information Global Positioning System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 7314 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 10557 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 10155 Pressure Regulating Solenoid: Service and Repair Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the range selector lever cable heat shield bolts (1). 3. Remove the range selector lever cable heat shield (2). 4. Disconnect the range selector lever cable (2) from the range select lever. 5. Remove the range selector lever cable retainer (1). 6. Remove the range selector lever cable (2) from the cable bracket. Page 20970 Disclaimer Page 15590 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 4282 16. Install the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar). Tighten the nuts to 50 Nm (37 lb ft). 17. Partially lower the vehicle. 18. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 19. Remove the J 42640 from the steering column lower access hole. Page 9073 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 15025 Page 6885 Page 20770 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 9736 Disclaimer Page 9393 4. Install the selective shim (1) on the shoulder on the differential pinion gear (2). Note Press the bearing on until the cone seats on the pinion shim. 5. Using the J 22828 - installer or the J 36614 - installer , install the inner pinion bearing. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . 8. Install the outer pinion bearing into the axle housing. 9. Install the differential pinion gear into the axle housing. Note DO NOT re-use the old pinion nut, replace with NEW only. Page 10674 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 6025 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 13875 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Component Locations Cellular Phone Microphone: Component Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 3124 Page 5662 Component Parts Page 20170 Marker Lamp: Service and Repair Roof Marker Lamp Replacement (U01) Roof Marker Lamp Replacement (U01) Page 9059 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 4576 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 12524 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 11878 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11842 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 13139 Page 8929 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat-bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Page 15015 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 17988 Disclaimer Page 13479 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10265 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 2715 Junction Block - Left I/P X4 (except MEX) Page 16031 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 8403 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 14049 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 10226 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 15228 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Rear of the Engine Compartment Components Page 9351 Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Page 7243 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Page 1517 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 12500 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 10216 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 15060 Page 12368 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 14863 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 9. Remove the safety stands. 10. Lower the vehicle. Page 11707 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Caster Description Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear . Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 11570 Page 5815 Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit, refer toData Link References (See: Initial Inspection and Diagnostic Overview/Data Link References) . Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer toDTC U0100-U0299 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100) . 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. Page 2356 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 18338 Removal Procedure Important: It is only necessary to lower the headlinder. Only do those steps in headlinder replacement that will lower the headlinder enough to grain access. 1. Lower the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure Page 16370 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 1851 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Page 16630 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 18344 Tighten the bolts to 10 Nm (89 lb in). 4. Install the remaining bolts at the motor base. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the front and rear drain hoses to the drain spigots. 6. Install the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)) . 7. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . Verify that the electrical connector is connected to the sunroof motor/actuator. 8. Install the sunroof window. Adjust as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Sunroof / Moonroof Panel/Adjustments)Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Sunroof / Moonroof Panel/Adjustments) . 9. Initialize the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Programming and Relearning) . 10. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair )Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair) . 11. Install the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)) . 12. Inspect the sunroof for proper operation. Page 12340 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 7912 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 5451 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 1469 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 4462 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Under the Front Seats Components Page 5005 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 13045 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 6889 Page 5309 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 11645 Page 18923 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Page 9607 1. Position the universal bearings in either side of the yoke on the propeller shaft. 2. Install the universal joint spider until it is seated in the universal bearing. 3. Press the universal joint spider until the bearing is even with the yoke. 4. Install the retaining ring (1) in the yoke (2). 5. Rotate the propeller shaft and repeat steps 1-4 for the opposite universal bearing. 6. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer and lightly tap the yoke to seat the universal bearing against the retaining ring. 7. Install the other two universal bearings and wrap them with electrical tape or equivalent to hold the bearing in place until the propeller shaft is installed in the vehicle. Page 3608 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 648 Body Control Module (BCM) X4 Page 11472 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in) . 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) 6. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Page 17385 Front Door Weatherstrip: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Front Side Door Upper Hinge and Lower Hinge Replacement Page 13379 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Page 10131 23 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Inner 24 - Transfer Case Front Output Shaft Drive Chain Assembly 25 - Transfer Case Front Output Shaft Drive Sprocket 26 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 27 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 28 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 29 - Transfer Case Oil Pump Assembly 30 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 31 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 32 Transfer Case Rear Output Shaft Rear Bearing Assembly 33 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 34 - Transfer Case Oil Pump Suction Pipe 35 - Transfer Case Oil Pump Suction Pipe Seal 36 - Transfer Case Front Output Shaft Driven Sprocket Spacer Spring 37 Transfer Case Front Output Shaft Driven Sprocket Spacer 38 - Transfer Case Front Output Shaft Driven Sprocket 39 - Transfer Case Front Output Shaft Hole Plug 40 - Transfer Case Front Output Shaft 41 - Transfer Case Front Output Shaft Front Bearing Assembly Page 13994 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 13555 Junction Block - Left I/P X5 (SPO Alarm) Page 10408 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 3469 12. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. 13. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See DIC Warnings and Messages. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. Your dealer/retailer has trained service people who will perform this work using genuine parts and reset the system. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message coming on, reset the system. Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the Engine Oil Life System: 1. Display the OIL LIFE REMAINING on the DIC. If the vehicle does not have DIC buttons, the vehicle must be in P (Park) to access this display. 2. Press and hold the SET/RESET button on the DIC, or the trip odometer reset stem if the vehicle does not have DIC buttons, for more than five seconds. The oil life will change to 100%. If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the Engine Oil Life System has not reset. Repeat the procedure. GM Oil Life System Resetting (From Service Manual) When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System (From Service Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the Page 12639 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 20785 1. Install the regulator (1) and cables (2) to vehicle. 2. Install the cable ends (1) to the window guide (2) at each end of the window. Page 17153 Page 9228 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12751 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (D07 with UQ3 or AZ3/HP2) Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 16990 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14765 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Page 5560 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 1064 Sliding Rear Window Open Relay (A48) Sliding Rear Window Switch (A48) Page 9091 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 18828 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 791 Page 12083 Page 15707 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab Except 10 Series) Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 12084 Fuse Block - Underhood X5 Page 8490 Extension Housing: Service and Repair Case Extension and Gasket Replacement Case Extension and Gasket Replacement Page 10394 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 70 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Testing and Inspection Transmission Mount: Testing and Inspection Transmission Mount Inspection Caution: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: Note Black paint on the rubber will crack with time, this does no constitute a failure. * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 3. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Page 12620 Page 4223 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13618 Fuse Block: Service and Repair 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Page 12613 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 15334 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 18586 For vehicles repaired under warranty, use the table above. Disclaimer Page 8112 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 1814 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 11934 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 3560 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 13000 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 19184 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Page 8204 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 13701 1 - X800 2 - Door Handle 3 - Door Frame Brake Clutch Harness Routing Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12422 Page 5748 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 2578 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings) . Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent . Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter . 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). Page 4882 Page 19038 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 1017 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 8119 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 3294 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Service and Repair Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the leaf spring assembly from vehicle. Refer to Leaf Spring Replacement (See: Service and Repair/Rear Suspension Leaf Spring) . 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the shackle nut and bolt to the spring. Tighten the shackle nuts to 95 Nm (70 lb ft). 3. Install the leaf spring assembly to the vehicle. Refer to Leaf Spring Replacement (See: Service and Repair/Rear Suspension Leaf Spring) . 4. Remove the safety stands. 5. Lower the vehicle. Page 13654 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 1671 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Locations Braking Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 13014 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 7714 Page 12373 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 15348 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 5125 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set Brake Bleeding: Technical Service Bulletins ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-05-25-006A Date: March 25, 2009 Subject: Hybrid Two-Mode Red Brake Telltale Illuminates Under High Braking Demand or Heavy Regenerative Braking, ABS Traction Control And/Or StabiliTrak Lights On With DTCs C056D 00, C12F3, C12F4 and C12F6 (Check Brake Pedal Travel and Bleed Brake System) Models: 2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Silverado Hybrid, Tahoe Hybrid 2008-2009 GMC Sierra Hybrid, Yukon Hybrid with Two-Mode Hybrid System (RPO HP2) with Active Apply, Disc/Disc, With VSES, With Regen, 7,700 lb Brake System (RPO J92) Supercede: This bulletin is being revised to add the 2009 Chevrolet Silverado and GMC Sierra Hybrid Truck Models. Please discard Corporate Bulletin Number 08-05-25-006 (Section 05 Brakes). Condition Some customers may comment that a red brake telltale illuminates in stop and go traffic under high braking demand or heavy regenerative braking and the ABS lamp is illuminated followed by a" Service Stability Message" displayed in the Driver Information Center. During diagnosis, the technician may find any or all of the following Electronic Brake Control Module (EBCM) and Electrical Control Module (ECM) diagnostic codes set: - C056D 00 : ECU Hardware Performance - C12F3 : ECU Hardware Performance (ABS Left Isolation Solenoid Valve Performance) - C12F4 : ECU Hardware Performance (ABS Right Rear Isolation Solenoid Valve Performance) - C12F6 : ECU Hardware Performance (ABS Proportioning Valve Solenoid Performance) Cause This condition may be caused by an incomplete brake bleeding procedure, allowing the control module to learn invalid actuator offsets. Correction Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to bleed the brake system. Ensure that the recommended procedures are followed to relieve system pressure, to avoid brake fluid spray. Failure to properly follow procedures to depressurize the system may result in personal injury or damage to the vehicle. Refer to Brake Fluid Irritant Warning and Brake Fluid Effects on Paint and Electrical Components Caution in SI. Note Install a midtronics battery charger or equivalent on the vehicle to maintain the battery voltage. Note The brake corners must be cool to obtain the most accurate measurement. Check the brake pedal travel and perform the automated brake bleed procedure with the Tech 2(R) following the procedure below. 1. Place the transmission in the PARK position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Page 5803 Accessory Wakeup Serial Data and Linear Interconnect Network (LIN) Page 14643 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 8712 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 11620 Battery Tray: Service and Repair Battery Tray Replacement Battery Tray Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions) . 1. Remove the battery. Refer to Battery Replacement (See: Service and Repair/Battery Replacement) . 2. Reposition the positive and negative battery cables out of the way. 3. Remove the battery tray to battery tray reinforcement bolts (1). 4. Remove the battery tray to battery tray support bolts (2). 5. Remove the battery tray to auxiliary bussed electrical center (BEC) bolt (4). 6. Remove the battery tray (3). Installation Procedure Page 2813 Page 19308 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Exhaust Seal Replacement Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Exhaust Seal Replacement (With V8 Engine) Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . 2. Remove and discard the appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). Installation Procedure 1. Install the NEW appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). 2. Install the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Page 1071 Page 7392 Actuator: Locations Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle (9.25 inch) Front Drive Axle (9.25 inch) 1 - Front Drive Axle Inner Shaft 2 - Front Drive Axle Inner Shaft Seal 3 - Front Drive Axle Inner Axle Shaft Bearing 4 - Front Drive Axle Inner Shaft Housing 5 - Front Drive Axle Clutch Gear Thrust Washer 6 - Front Drive Axle Clutch Gear 7 - Front Drive Axle Inner Shaft Retaining Ring 8 - Front Drive Axle Clutch Sleeve 9 - Front Drive Axle Clutch Shim 10 - Front Drive Axle Actuator 11 - Front Drive Axle Inner Shaft Housing Bolt 12 - Front Drive Axle Clutch Fork Assembly 13 - Front Drive Axle Clutch Fork Inner Spring 14 - Front Drive Axle Clutch Shaft Bearing 15 - Front Drive Axle Clutch Shaft 16 - Front Differential Carrier Bolt 17 - Front Differential Carrier 18 - Front Differential Carrier Half Location Pin 19 - Front Differential Case Bearing 20 - Front Differential Bearing Adjuster Nut 21 - Front Differential Bearing Adjuster Nut Sleeve 22 - Front Differential Side Bearing Cup 23 - Differential Ring Gear Bolt 24 - Front Differential Side Bearing 25 - Front Differential Pinion Gear Shaft Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 2297 Spark Plug: Application and ID Ignition System Specifications Interior - Wear Spots On Vinyl/Rubber Floor Covering Carpet: Customer Interest Interior - Wear Spots On Vinyl/Rubber Floor Covering TECHNICAL Bulletin No.: 08-08-110-013 Date: August 18, 2008 Subject: Premature Wear or Worn Spots on Rubber/Vinyl Floor Covering (Replace Floor Covering) Models: 2007-2009 Chevrolet Silverado, Silverado HD, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra HD, Yukon, Yukon XL with Rubber Floor Covering (RPO BG9) Including Police (RPO PPV) and Municipal (RPO 5W4) Vehicles EXCLUDING Standard and Crew Cab Models Condition Some customers may comment on premature wear or worn spots (1) on the front rubber/vinyl floor covering. Correction Important: The standard and crew cab models already have the updated floor mat material. Replace the affected floor covering. Refer to Floor Panel Carpet Replacement in SI. The mat floor covering material has been updated to reduce premature wear. Parts Information Page 17664 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 8679 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Page 7198 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: All Technical Service Bulletins Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15064 Page 18060 Door Lock/Window Switch - Driver X7 (AN3/DL3) Page 8243 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 7474 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 11730 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7592 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) Page 12316 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6120 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 11023 Page 20642 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Passenger Compartment/Roof Component Views Overhead Console Components Page 6377 Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure Note Clean all evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting, in order to avoid possible EVAP system contamination. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the EVAP line quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 11920 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 3130 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 4200 Page 20602 Window Switch - Passenger (A31 without AN3/DL3) Page 16726 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 3568 Note The crankshaft balancer is balanced as an individual component. It is not necessary to mark the balancer prior to removal. 6. Use the J 41816-A and the J 41816-2 to remove the crankshaft balancer (138). 7. Remove the J 41816-A and the J 41816-2 from the crankshaft balancer. Installation Procedure Note * The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and fourth passes tighten the NEW bolt to the proper torque. * The used crankshaft balancer bolt will be used ONLY during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and fourth passes of the balancer bolt tightening procedure. Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: All Technical Service Bulletins Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Page 9003 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 19567 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 2052 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 11352 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 16646 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in) . 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 18709 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) MP 1222/1225/1226-NQG - Transfer Case Transfer Case Actuator: Locations MP 1222/1225/1226-NQG - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 11148 4. Connect the brake pedal pushrod while simultaneously installing the stoplamp switch (1). 5. Install the brake pushrod retainer (1). Rotate the brake pushrod retainer 360 degrees to ensure the retainer is fully engaged in the brake pedal pushrod pivot pin groove. Page 10434 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 16653 Audio Amplifier X3 (UQA) Page 15274 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 16328 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 18916 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 15705 Page 15108 Control Module HVAC: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 1904 Page 12938 Switches and Relays Page 8851 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 11277 Parking Brake Cable Guide Replacement Parking Brake Cable Guide Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake cable guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the park brake cable guide bolt to the frame and tighten to 12 Nm (106 lb in) . 4. Lower the vehicle. Page 20493 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 10775 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 4054 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 5500 Crankshaft Position (CKP) Sensor (Diesel) Page 17147 Page 4252 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 187 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 9834 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13183 Page 2931 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 13132 Fuse Block - Auxiliary X1 (HP2) Page 13466 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9843 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 6812 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) Page 17227 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 3693 Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Side (1500 Except RPOs LY6, LY2) Removal Procedure Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. If the vehicle is equipped with four wheel drive (4WD), remove the front drive axle. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . 2. Lower the vehicle. 3. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 4. Remove the engine mount to frame bolts (1). 5. Raise and support the vehicle halfway. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . Page 3013 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 1912 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 5695 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 3619 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20501 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 1339 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 497 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 15335 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 6062 3. Position the engine wiring harness electrical connectors and engage the retainers securing the connectors (2) to the ECM (1). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 19414 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 723 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 7349 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11950 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 17793 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6461 6. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid. 7. Install EVAP canister vent solenoid clip (1) to the chassis EVAP line. 8. Install the EVAP canister vent solenoid pipe to the clip (2) on the chassis EVAP line. 9. Install the EVAP canister vent solenoid pipe to the clips (3) on the brake pipes. 10. Lower the vehicle. Page 7969 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 15988 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (Except 10 Series) Page 3330 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 14196 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12871 IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Disclaimer Page 9796 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 11012 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Page 1445 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 3518 4. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Page 18565 Seat Bladder: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 10340 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 2922 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7301 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 17424 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Page 5767 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 9394 10. Install the NEW differential pinion oil seal, flange/yoke, and the NEW nut and washer. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 11. Using an inch-pound torque wrench, measure the rotating torque of the pinion should be between1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 12. If the rotating torque measurement is below1.0 Nm (10 lb in) for used bearings, or1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut in small increments, until the torque required in order to rotate the pinion is between1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 13. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. 14. Recheck the rotating torque of the pinion bearing and adjust if necessary. 15. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 16. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle) )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 17. Remove the support and lower the vehicle. Page 6468 Evaporative Emissions Hose: Service and Repair Evaporative Emission Line Replacement Canister to Tank Evaporative Emission Hoses/Pipes Replacement - Canister/Fuel Tank Removal Procedure Note Clean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible EVAP system contamination. 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank shield retainers (2, and 3) and shields (1, and 4). 3. Remove the EVAP lines from the fuel tank clips (2, and 6). Page 10329 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 14875 Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 1649 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . Page 4067 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 4. If the right side spark plug wire(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 14732 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 20547 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Warning When carrying an undeployed inflatable restraint seat belt pretensioner: * Do not carry the seat belt pretensioner by the wires or connector. * Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. * Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. * Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt pretensioner in the following situations: * After replacement of a seat belt pretensioner under warranty. The seat belt pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt pretensioner connector is damaged. * The seat belt pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Special Tools * J 39401-B SIR Deployment Fixture * J 38826 SIR Deployment Harness * An appropriate pigtail adaptor Engine Coolant Fan Lower Shroud Replacement Fan Shroud: Service and Repair Engine Coolant Fan Lower Shroud Replacement Engine Coolant Fan Lower Shroud Replacement (Mechanical) Removal Procedure 1. Remove the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair) . 2. Disengage the two clips from the radiator. 3. If equipped with engine oil cooler , remove the oil cooler hose clip from the lower fan shroud. 4. Remove the shroud from the vehicle. Installation Procedure 1. Install the lower fan shroud and ensure it is centered over lower radiator support. 2. Engage the two clips from the radiator. 3. If equipped with the engine oil cooler , Install the oil cooler hose clip to the lower fan shroud. 4. Install the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair) . Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Page 10391 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7928 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 802 Page 7715 Component Parts Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 3694 Note DO NOT raise and/or support the engine by the crankshaft balancer, or the oil pan. 6. Place an adjustable (screw type) jack to the tab (1) located on the engine block. 7. Remove the left side exhaust manifold heatshield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (4.3L) ()Exhaust Manifold Heat Shield Replacement - Left Side (4.8L, 5.3L, 6.0L, and 6.2L) () . 8. Remove the engine mount to engine bolts (1). 9. Using the adjustable jack, raise the engine slightly until there is enough clearance to remove the engine mount. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 9935 Drivetrain - Clunk Noise At A Stop Or From Launch Slip Yoke: Customer Interest Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 20476 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5164 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 7448 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Interior - Lint Accumulation On Ebony Colored Seats Arm Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 7947 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 8126 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Restraints/Interior - Front Seat Belt Twisted Seat Belt: All Technical Service Bulletins Restraints/Interior - Front Seat Belt Twisted TECHNICAL Bulletin No.: 07-09-40-001A Date: May 14, 2009 Subject: Front Seatbelt Latch Plate Reversed, Front Seatbelt Twisted (Perform Repair to Untwist Seatbelt) Models: 2008-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 Saturn OUTLOOK .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the Traverse model and the 2009 model year. Please discard Corporate Bulletin Number 07-09-40-001 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the seatbelt latch plate is reversed on the belt webbing or that they have to twist the webbing before buckling the seatbelt. This condition can be visually verified by inspecting the location of the latch plate tongue. If the tongue is between the webbing and the pillar post, it is reversed. Correction Do NOT replace the seatbelt retractor for this condition. To correct this condition, perform the following repair. 1. Pull the majority of the belt webbing out of the retractor. 2. With the latch plate resting at its lowest point, take the webbing above the latch plate and fold the webbing over itself at a 45 degree angle. Pinch the folded portion between the thumb and forefinger. 3. Using the other hand, pull the latch plate up over the fold until past the doubled over section. Page 7861 ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set Brake Bleeding: Technical Service Bulletins ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-05-25-006A Date: March 25, 2009 Subject: Hybrid Two-Mode Red Brake Telltale Illuminates Under High Braking Demand or Heavy Regenerative Braking, ABS Traction Control And/Or StabiliTrak Lights On With DTCs C056D 00, C12F3, C12F4 and C12F6 (Check Brake Pedal Travel and Bleed Brake System) Models: 2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Silverado Hybrid, Tahoe Hybrid 2008-2009 GMC Sierra Hybrid, Yukon Hybrid with Two-Mode Hybrid System (RPO HP2) with Active Apply, Disc/Disc, With VSES, With Regen, 7,700 lb Brake System (RPO J92) Supercede: This bulletin is being revised to add the 2009 Chevrolet Silverado and GMC Sierra Hybrid Truck Models. Please discard Corporate Bulletin Number 08-05-25-006 (Section 05 Brakes). Condition Some customers may comment that a red brake telltale illuminates in stop and go traffic under high braking demand or heavy regenerative braking and the ABS lamp is illuminated followed by a" Service Stability Message" displayed in the Driver Information Center. During diagnosis, the technician may find any or all of the following Electronic Brake Control Module (EBCM) and Electrical Control Module (ECM) diagnostic codes set: - C056D 00 : ECU Hardware Performance - C12F3 : ECU Hardware Performance (ABS Left Isolation Solenoid Valve Performance) - C12F4 : ECU Hardware Performance (ABS Right Rear Isolation Solenoid Valve Performance) - C12F6 : ECU Hardware Performance (ABS Proportioning Valve Solenoid Performance) Cause This condition may be caused by an incomplete brake bleeding procedure, allowing the control module to learn invalid actuator offsets. Correction Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to bleed the brake system. Ensure that the recommended procedures are followed to relieve system pressure, to avoid brake fluid spray. Failure to properly follow procedures to depressurize the system may result in personal injury or damage to the vehicle. Refer to Brake Fluid Irritant Warning and Brake Fluid Effects on Paint and Electrical Components Caution in SI. Note Install a midtronics battery charger or equivalent on the vehicle to maintain the battery voltage. Note The brake corners must be cool to obtain the most accurate measurement. Check the brake pedal travel and perform the automated brake bleed procedure with the Tech 2(R) following the procedure below. 1. Place the transmission in the PARK position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Page 11434 5. Slide the trailer brake control module (1) toward the center of the vehicle and remove the trailer brake control module. Installation Procedure 1. If installing a new trailer brake control module, hand start the 3 trailer brake control module bolts. 2. Position the trailer brake control module to the frame bracket. 3. Slide the trailer brake control module (1) toward the left frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 12863 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 1770 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 12072 Page 15535 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 6321 1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the CMP actuator magnet (752) to the front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the CMP actuator magnet bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the water pump. Refer to Water Pump Replacement . Page 3061 Junction Block - Right I/P X4 Page 6214 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 13597 Fuse Block - Underhood X6 Page 13997 For vehicles repaired under warranty, use the table. Disclaimer Page 3538 2. Install the rear oil seal housing bolts (1) until snug. Do not overtighten. 3. Rotate the crankshaft until 2 opposing flywheel bolts holes are parallel to the oil pan surface. Note The tapered legs of the alignment tool must enter the rear cover oil seal bore. 4. Install the J 41476 and bolts onto the rear of the crankshaft. 5. Tighten the J 41476 bolts until snug. Do not overtighten. 6. Install the oil pan-to-rear oil seal housing bolts (1). 1. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 2. Tighten the rear oil seal housing-to-engine bolts to 30 Nm (22 lb ft). 7. Remove the J 41476 . 8. Install a NEW crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair) . 9. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair) . Page 18247 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 13800 X109 Inline Harness Connector End Views X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (Except NQF/NQH/HP2/Late Production with 4.8L/5.3L/6.0L/6.2L) Page 7154 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13547 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Engine - Oil Consumption On Aluminum Block Engines Piston Ring: All Technical Service Bulletins Engine - Oil Consumption On Aluminum Block Engines TECHNICAL Bulletin No.: 10-06-01-008B Date: March 07, 2011 Subject: Engine Oil Consumption on Aluminum Block Engines with Active Fuel Management (AFM) (Install AFM Oil Deflector and Clean Carbon from Cylinder) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2007-2009 GMC Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2009 Pontiac G8 GT Equipped with Aluminum Block V8 Engine with Active Fuel Management (AFM) (RPOs LC9, LH6, L76, LFA, L92) with Greater than 45,000 km (28,000 mi) Supercede: This bulletin is being revised to add the 2009 model year and new Correction information for the 2009 model year - left rocker arm cover replacement. Information has also been added after step 9. Please discard Corporate Bulletin Number 10-06-01-008A (Section 06 Engine/Propulsion System). Condition Some customers may comment about engine oil consumption of vehicles with higher mileage (approximately 48,000 to 64,000 km (30,000 to 40,000 mi). Verify that the induction system is assembled correctly and that there is no evidence that the engine has been ingesting dirty air due to a mis-assembled induction system. Also verify that the PCV system is functioning properly. If diagnostic procedures indicate that oil consumption is piston /piston ring related, verify that oil consumption is less than 3,000 km (2,000 mi) per liter/quart. If these conditions are met and oil consumption is less than 3,000 km (2,000 mi) per liter/quart, perform the service indicated in this bulletin. Cause This condition may be caused by oil spray that is discharged from the AFM pressure relief valve within the crankcase. Under most driving conditions and drive cycles, the discharged oil does not cause a problem. Under certain drive cycles (extended high engine speed operation), in combination with parts at the high end of their tolerance specification, the oil spray quantity may be more than usual, resulting in excessive deposit formation in the piston ring grooves, causing increased oil consumption. Correction 2009 Vehicles Only Important This left rocker arm cover is NOT to be used on 2007-2008 vehicles because of the calibration of the PCV orifice being different in 2007-2008. A new left rocker arm cover has been released for 2009 engines. Technicians should replace the left rocker arm cover with GM P/N 12642655. This rocker arm cover has relocated PCV drain holes that prevents PCV pullover into the intake manifold. Refer to SI for Valve Rocker Arm Cover Replacement - Left Side. 2008-2007 Vehicles Only To correct this condition, perform the piston cleaning procedure as described in this document, and install a shield over the AFM pressure relief valve per the procedure outlined in this document. Monitor oil consumption after this repair to ensure oil consumption has improved to acceptable levels. If this repair does not correct the condition, it may be necessary to replace the piston assemblies (piston and rings) with new parts. Important It is critical in this cleaning process that the engine/fuel injector cleaner remain in the cylinders for a minimum of 2.5 hours to fully clean the components. The cleaner solution must be removed before a maximum of three hours. 1. Verify the oil consumption concern following Corporate Bulletin Number 01-06-01-011F. If oil consumption is found, continue on with this bulletin. 2. Remove the spark plugs and ensure that none of the pistons are at top dead center (TDC). 3. Clean the pistons by putting 118-147 ml (4-5 oz) of Upper Engine and Fuel Injector Cleaner, GM P/N 88861802 (in Canada, use 88861804), in each cylinder. Allow the material to soak for at least 2.5-3.0 hours, but no more than three hours and then remove the cleaner. A suggested method Auxiliary Fluid Pump Control Module Replacement Fluid Pump: Service and Repair Auxiliary Fluid Pump Control Module Replacement Auxiliary Fluid Pump Control Module Replacement Removal Procedure 1. Disconnect the auxiliary fluid pump electrical wire harness connector (1) from the auxiliary fluid pump control module connector (2). 2. Disconnect the auxiliary fluid pump control module electrical connector (1) from the engine wiring harness electrical connector (2). Page 14354 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Body - Outside Door Handle Pulls Out of Base Front Door Exterior Handle: Customer Interest Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11663 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 7744 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 12767 X700 Left Rear Door Harness to Body Harness (Extended Cab) Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 19445 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 7065 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8471 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Page 15286 Page 10374 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12515 Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 1968 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7))Front Brake Rotor Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) . 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7))Front Brake Rotor Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) . 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 4. Lower the vehicle. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 4626 * Accessory DC power control module (APM) * Battery energy control module (BECM) * Motor control module (MCM) 1 * Motor control module (MCM) 2 * Auxiliary transmission fluid pump (ATFP) control module These modules diagnose their own operation and determine when a fault condition is present. Diagnostic status is communicated to the HPCM through the following circuits: * APM utilizes the GM Hi-speed, Hybrid LAN communication circuit * BECM utilizes the GM Hi-speed, Hybrid LAN communication circuit * Each MCM and the HPCM exchange information and commands on the SPI bus internal communication circuit as well as the hi-speed hybrid GMLAN communication circuit. * ATFP control module utilizes a dedicated diagnostic status circuit In the event a hosted module communicates a fault condition, the HPCM will determine if hybrid operation is effected and notify the vehicle operator by requesting the MIL illuminate and/or by displaying a hybrid service required message. In addition, the HPCM will store the associated DTC information for retrieval by a scan tool. Some hosted modules may require an ignition cycle to clear certain DTCs from the HPCM. Circuit Inputs In addition to GMLAN parameters, the HPCM directly monitors the following signal circuits: * Transmission shift selector internal mode switch (IMS) Direction and Park/Neutral switch signals * Engine crankshaft position (CKP) sensor signal * ATFP diagnostic circuit * High voltage interlock circuit (HVIC) Circuit Outputs In addition to GMLAN and SPI bus commands, the HPCM directly controls the following output circuits: * ATFP control circuit * BECM high voltage contactor relay pulse width modulated (PWM) control circuit Motor Control Module (MCM) 1 and 2 Location Each electric motor generator located within the transmission assembly is controlled by its own motor control module (MCM) flash-programmable, micro-processor. Each MCM is contained within the PIM. Also contained within the PIM is the hybrid powertrain control module (HPCM) micro-processor. Operating Functions Each MCM operates the applicable electric motor generator based upon HPCM commands. Each MCM controls the speed, direction and output torque of its respective traction motor through the sequencing actuation of high current switching transistors called insulated gate bipolar transistors (IGBTs). Communication and Hosted Diagnostics In addition to the internal SPI bus communication circuit between the HPCM and each MCM, the MCMs also communicate on the Hi-speed and Hybrid GMLAN communication circuits. The MCM does not store its own diagnostic trouble code (DTC) information. The HPCM will store MCM associated DTC information for retrieval by a scan tool. The scan tool can communicate directly with each MCM in order to retrieve data parameters only. Circuit Inputs In addition to GMLAN parameters, each MCM monitors its respective motor generator for voltage, current, speed, direction and temperature. Additionally, the MCM monitors the IGBT components for temperature and proper operation. Some of the MCM operation data is shared with the HPCM. Circuit Outputs Each MCM controls its respective IGBT driver board that in-turn controls each motor generator. The motor generators operate using three-phase alternating current (AC) electricity. Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician that the potential for high voltage is present. Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 13332 Page 12472 Fuse Block - Underhood X2 Page 14959 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Page 8584 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13871 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Page 15087 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 7312 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 18807 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 3695 10. Remove the engine mount. Installation Procedure 1. Position the engine mount to the engine. Page 15327 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6391 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11043 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Page 3439 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Page 16164 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7094 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. 6. Install the range selector lever cable heat shield (2). 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. Page 798 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (Gas with LY6) Page 2020 Page 7257 Devices and Sensors Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Page 7534 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Page 5214 Right Side of the Engine Components (Diesel) 1 - Fuel Injector 7 2 - Fuel Injector 5 3 - Fuel Injector 3 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Fuel Injector 1 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 7 - Intake Air Valve 8 - Crankshaft Position (CKP) Sensor 9 - Glow Plug 1 10 - G103 11 - G105 12 - Block Heater 13 - Glow Plug 3 14 - Glow Plug 5 15 - Water In Fuel Sensor 16 - Starter Motor 17 - Glow Plug 7 Rear of the Engine Components (Diesel) Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 5871 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 7996 27 - Differential Pinion Thrust Washer 28 - Differential Pinion Gear 29 - Differential Side Gear Washer 30 - Differential Side Gear 31 - Output Shaft Snap Ring 32 - Differential Pinion Gear 33 - Differential Pinion Gear Thrust Washer 34 - Differential Side Gear 35 - Differential Side Gear Washer 36 - Differential Cross Pin 37 - Ring Gear Bolt 38 - Output Shaft Bearing Assembly 39 8-Point Lock Ring 40 - Sleeve and Insert Assembly 41 - Differential Side Bearing Assembly 42 Carrier Gasket 43 - Carrier Cover 44 - Tube Locator Pin 45 - Inner Output Shaft Thrust Washer 46 - Inner Output Shaft Bearing Assembly 47 - Inner Output Shaft 48 - Carrier Bolt 49 - Shifter Spring 50 - Shifter Fork 51 - Shifter Fork Rod 52 - Tube Bolt 53 - Shift Actuator Assembly 54 - Output Shaft Seal Assembly 55 - Output Shaft Bearing Assembly 56 - Tube 57 - Tube Gasket 58 - Output Shaft Locator Thrust Washer 59 - Output Shaft Thrust Washer 60 - Output Shaft Snap Ring 61 Shifter Sleeve Page 12702 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 10424 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 15091 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 20401 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Page 14870 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 8245 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 4535 Drive Motor Control Module: Service and Repair Drive Motor Generator Control Module Assembly Replacement Drive Motor Generator Control Module Assembly Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 3. Disconnect the drive motor generator control module assembly connector (1). 4. Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . Page 11753 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 11901 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 14649 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 16915 For vehicles repaired under warranty, use the table. Disclaimer Page 1665 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . Page 6288 Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (3). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (6). Page 4117 Page 4430 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 4375 3. If vehicle has a extended cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. 4. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in) . 5. If vehicle has a regular cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the studs. 6. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in) . 7. Install the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . Page 16270 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Page 9043 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 19234 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 19081 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Page 1903 Camshaft Position (CMP) Sensor (Diesel) Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 16923 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Grille: Service and Repair Radiator Grille Replacement (Chevrolet) Page 12724 X212 Instrument Panel Harness to Instrument Panel Extension Harness (Early Production Except Y91/MEX/HP2/8S8) Page 17566 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Page 2203 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 7403 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD and SHD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Inserts 12 - Transfer Case Shift Fork Spring 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case High/Low Shift Fork 15 - Transfer Case High/Low Shift Fork Inserts 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case Shift Detent Lever Assembly 18 - Transfer Case Rear Output Shaft 19 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 20 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 21 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 22 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Outer Page 10791 Inspection/Component Tests and General Diagnostics/Brake System Internal Leak Test) andBrake Pedal Travel Measurement and Inspection (Non-Hybrid) (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection)Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection) . 73. If internal leaks are found, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 74. If the brake pedal travel exceeds specification and there is no damage to the pedal system or pushrod, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 75. Turn the ignition switch to ON, without starting the engine. Observe if the brake system warning lamp remains illuminated. 76. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until the brake system is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . 77. Start the engine. 78. Firmly apply the brake pedal several times. Observe the brake pedal feel. 79. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. 80. Drive the vehicle to a speed above 13 km/h (8 mph) to allow ABS initialization to occur. Observe the brake pedal feel. 81. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 18856 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Body - Outside Door Handle Pulls Out of Base Rear Door Exterior Handle: Customer Interest Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Removal Procedure Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to service the HPA. Ensure that the recommended procedures are followed to relieve system pressure, including using the manual pressure release steps. Failure to properly follow procedures to depressurize the system may result in personal injury. Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the antilock brake system (ABS) module splash shield retainer (1). Page 20178 Page 11731 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2704 Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Fuse Holder X4 (Engine Chassis Harness) (Diesel) Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 5746 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 13454 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 7362 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 10015 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Page 10477 Clutch Components 1 - Transfer Case Rear Output Shaft 2 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 3 - Transfer Case Control Lever 4 - Transfer Case Control Actuator Lever Bearing Assembly 5 - Transfer Case Control Actuator Lever Ball (Qty: 3) 6 - Transfer Case Control Actuator Lever Assembly 7 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 8 - Transfer Case Control Actuator Lever Washer 9 - Transfer Case Four Wheel Drive Clutch Pressure - Apply Plate Suspension - Multiple Noises From Front Of Vehicle Suspension Travel Bumper: All Technical Service Bulletins Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Page 6539 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 242 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 7878 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 18165 Paint: Application and ID Paint Identification Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note Always refer to the GM Approved Refinish Materials book . This book identifies the paint systems you may use. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) . Component Locations Trailer Connector: Component Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 639 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 4735 Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 7964 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 19366 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 13011 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 14396 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 13780 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (D07 with UQ3 or AZ3/HP2) A/T - Valve Body Reconditioning Info. Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Info. INFORMATION Bulletin No.: 08-07-30-006A Date: October 13, 2009 Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel Drive Automatic Transmission Control Valve Body Assembly Reconditioning Models: 2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45, 6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA, MYB, MYC, MYD) Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 Transmission/Transaxle). The information outlined in this bulletin is designed to provide easy to follow control valve body reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50, 6L80 and/or 6L90 automatic transmission control valve body assembly. Caution Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Notice After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. Notice Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may damage the component. Inspection Procedure for Shift Concerns 1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve body. Describe the restricted valve on the repair order. Disassembly/Reassembly for Cleaning Debris 1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr. Inspect the movement in the valve's normal position. If no other debris or restrictions are found, reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure, disassemble all bores for complete cleaning of all valve body components. Keeping individual bore parts separated will make reassembly easier. Use the following illustrations for positive identification and location of individual parts. 3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Page 7862 Devices and Sensors Page 9352 Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Interior - Carpet Curling At Front Edge Carpet: Customer Interest Interior - Carpet Curling At Front Edge TECHNICAL Bulletin No.: 09-08-110-002 Date: January 27, 2009 Subject: Carpet Curling at Front Edge (Install Velcro Fastener) Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Condition Some customers may comment that the carpet is curling at the top front edge (1). Cause The front edge of the carpet assembly may be folded before installation into the vehicle at the time of manufacture. After installation, the edge of the carpet may begin to curl due to the fold condition. Correction Important: Do not replace the carpet assembly. Use the following steps to correct the condition. 1. Clean the carpet backing and the dash pad surface with general purpose adhesive cleaner in the area where the Velcro is to be applied. 2. Install two 100 mm (3.90 in) long strips of Velcro loop material, GM P/N 12520273, to the dash pad as shown (1). 3. Install two 100 mm (3.90 in) long strips of Velcro hook material, GM P/N 12520271 to the corresponding area of the carpet assembly. 4. Apply firm pressure to the repair area to ensure that the adhesive backing on the Velcro bonds to the surface. Warranty Information Page 177 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 1358 Page 3842 6. Place a suitable drain pan under the oil pan drain plug. 7. Remove the oil pan drain plug (430). 8. Allow the oil pan to drain completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 9. Re-install the oil pan drain plug. Tighten the oil pan drain plug to 25 Nm (18 lb ft). 10. Place the drain pan under the oil filter. 11. Remove the oil filter (437). 12. Allow the oil to drain completely. 13. Re-install the oil filter. Tighten the oil filter to 30 Nm (22 lb ft). Page 10244 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 4995 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12280 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 14989 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 5628 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 20590 Door Lock/Window Switch - Driver X4 (AN3) 08-08-49-016C - END OF INFORMATION NEED Fuel Gauge Sender: Technical Service Bulletins 08-08-49-016C - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 08-08-49-016C Date: May 21, 2009 Subject: EI08347 - DTC P0463, Fuel Gauge/Gage Inaccurately Reads Empty, Low Fuel Light On (Diagnose and Repair Using SI) Models: 2008-2009 Buick Lucerne 2008-2009 Chevrolet Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 08-08-49-016B (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. This bulletin is being revised to end the need for dealer feedback. If you encounter a vehicle with this concern, please diagnose and repair using the information found in SI. Disclaimer Page 13521 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Page 10070 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal ontoJ 43484 . 3. UsingJ 43484 (2), andJ 8092 (1), install the seal. 4. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 7. Lower the vehicle. Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Tools Required J 45756 Output Shaft Seal Installer Removal Procedure Page 3678 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory) . Page 10458 Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 1387 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 17949 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Page 7043 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 5090 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 12720 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 9004 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 415 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Page 18047 Page 20117 Page 1534 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 7483 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 5618 3. Position the engine wiring harness electrical connectors and engage the retainers securing the connectors (2) to the ECM (1). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 1238 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5581 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 6479 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 7909 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 16102 Page 15538 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 833 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6530 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 19640 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 3616 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 11502 Locations Oxygen Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 2758 Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 6433 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 19634 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 9481 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Page 7688 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 7066 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 9496 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half ofJ 36652-1 orJ 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts intoJ 36652-1 orJ 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair/Front Wheel Drive Shaft Seal Protector Replacement) . 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Page 2644 Fuse Block - Underhood X3 Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 6026 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 2932 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 20227 Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 18664 Seat Cushion: Service and Repair Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Page 10368 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 9412 * For vehicles equipped the a one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with a two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . Note The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement) . 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . 16. Remove the support and lower the vehicle. Page 18459 Memory Seat Module (MSM) X5 (AN3) Page 1453 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Page 6323 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 12114 Junction Block - Left I/P X10 (except MEX) Page 18607 Disclaimer Page 5054 Crankshaft Position (CKP) Sensor (Diesel) Page 9525 9. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 10. Install the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note If the wheel hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the wheel hub seal must be replaced. 12. Install the wheel hub to the axle housing. 13. Using the J 2222-C - wrench , install the adjusting nut to the hub. 14. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) . 15. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) . 16. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 17. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 18. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . 19. Lower the vehicle. Page 7745 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 13399 Switch Position Icons Locations Power Window Relay: Locations Passenger Compartment/Roof Component Views Rear of the Passenger Compartment Components 1 - Information Center Telltale Assembly (UD7) 2 - Sliding Rear Window Open Relay (A48) 3 Sliding Rear Window Close Relay (A48) 4 - Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) 5 - Sliding Rear Window Motor (A48) Page 2815 Page 3519 6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 7. Remove the EN 46330 . Locations Seat Memory Switch: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Component Locations Seat Occupant Sensor: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 13614 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 17888 Page 12054 Page 10181 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 5749 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 3082 Restraint System - Normal Safety Belt Locking Conditions Seat Belt: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 19555 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 10212 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 19130 6. Using a suitable tool, at the center of the rod, bend one leg of the rod towards the center as shown (1). The object is to make one end of the "U" shaped section of the rod close to a 90 degree bend. Take care not the twist the rod as you bend it. 7. Using the same tool, straighten the rod at the other bend shown (1) until the rod is back straight. Take care not to twist the rod as you bend it. 8. Inspect the rod standing up on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 9. Inspect the rod laying flat on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 10. Inspect the overall length of the rod as shown. The overall length of the rod should be 3-4 mm (0.118-0.157 in) shorter. If the length is not correct, rebend the rod using the steps above to achieve the correct length. Page 10055 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 1701 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Fuel Hose/Pipes Replacement - Chassis Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis Fuel Hose/Pipes Replacement - Chassis Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 11055 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. Page 753 Page 4894 Page 641 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 3105 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Page 20781 Rear Door Window Regulator: Service and Repair Rear Sliding Window Regulator Replacement Rear Sliding Window Regulator Replacement Removal Procedure Note The new rear sliding window regulator and cables are serviced as an assembly. 1. Cycle the rear sliding window to the halfway position. 2. Remove the rear lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Note Use a suitable tool to lift upward on the rear sliding window stops (1) to remove. 3. Remove the rear sliding window stops (1). Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 7241 Control Solenoid Valve Assembly X3 (MYC/MYD) 1-2 Shift Solenoid (SS) Valve (M30) Page 8870 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Global Positioning System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 6212 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 8129 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 1420 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 106 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 8936 Note Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 12. Install the range selector cable to the support. 13. Install the cable to the steering column bracket. 14. Ensure the tangs fully engage into the steering column bracket. 15. Install the cable end to the steering column ball stud. Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 13712 X109 Inline Harness Connector End Views X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (Except NQF/NQH/HP2/Late Production with 4.8L/5.3L/6.0L/6.2L) Page 18957 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (except AN3/DL3) Page 10479 Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF/NQH) Page 6466 Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 4. Remove the EVAP rear pipe from the fuel tank clips (1 and 2). 5. Disconnect the small EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Installation Procedure 1. Position and connect the small EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Page 10823 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 8206 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 5050 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 14289 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 13535 Fuse Block - Auxiliary (HP2), Top View Page 11096 7. Through the frame crossmember, install the BPMV bracket bolts (1) and tighten to 22 Nm (16 lb ft) . 8. Tighten the lower BPMV bracket bolt (1) to 22 Nm (16 lb ft) . Page 3494 Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Valve Lifter Replacement Removal Procedure 1. Remove the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair) . 2. Remove the valve lifter guide bolts (211). 3. Remove the valve lifter guides (210) with the lifters. Note the installed position of the guides. The notched area of the guides is to align with the locating tab on the engine block. 4. Remove the valve lifters (209) from the guide (210). 5. Organize or mark the components so that they can be installed in the same location from which they were removed, if required. 6. Clean and inspect the valve lifters, if required. Refer to Valve Lifter and Guide Cleaning and Inspection (See: Service and Repair/Overhaul) . Installation Procedure Note When reusing valve lifters, install the lifters to their original locations. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 1177 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 4943 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 371 Seat Climate Control Module X3 (KB6) Page 12815 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Service and Repair Heater Hose: Service and Repair Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Page 17030 Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components (X88) Page 7502 Page 17508 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Page 4451 Drive Motor Generator Battery Control Module X3 (HP2) Page 7882 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 561 Page 10546 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 9459 Note Ensure that the axle shaft bearing is fully seated in the rear axle shaft housing. 2. Using the J 23690 - installer (1) and the J 8092 - driver (2), install the axle shaft bearing. 3. Using the J 21128 - installer , install the axle shaft seal. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair) . 6. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 8. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Differential Assembly/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 9. Remove the support and lower the vehicle. Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Page 6702 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Page 19375 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9492 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Page 12484 Fuse Block - I/P Top View Page 466 Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7880 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5542 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 5226 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 17928 Disclaimer Page 15983 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 4401 Battery, Hybrid Drive: Diagrams Component Connector End Views Drive Motor Generator Battery X1 (HP2) Drive Motor Generator Battery X2 (HP2) Page 9571 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Page 14231 1. Install the power steering fluid cooler (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the power steering fluid cooler bolts (2). Tighten the bolts to 9 Nm (80 lb in) 3. Connect the power steering fluid cooler hose (4) to the power steering pump (1). 4. Connect the power steering fluid cooler hose (3) to the steering gear (2). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair) . 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding () . Page 7885 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 3150 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 1351 1 - Wheel Speed Sensor (WSS) -Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) -Left Front (JL4/JF3/JF7/JH6/JH7) Front Frame and Underbody Components - 2 of 2 Page 6711 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 15398 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Page 4950 Page 9211 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Locations Steering Mounted Controls Assembly: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Engine - Valve Lifter Tick Noise At Start Up Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 7890 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 2057 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Frame Front Crossmember Replacement Cross-Member: Service and Repair Frame Front Crossmember Replacement Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 2952 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15442 * Remove the SIR coil from the steering column and allow the coil to hang freely before the shaft is rotated. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . * Visually inspect the steering shaft for sheared injected plastic (1). If the steering shaft shows sheared plastic, replace the steering shaft. * Inspect the steering shaft runout for any frame damage that could cause a bent steering shaft. Using a dial indicator at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.0625 in). Page 870 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 16183 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 3. Remove the fill plug. 4. Remove the drain plug. Note Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Page 16455 Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation The garage door opener (GDO) is fixed and rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit . When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-866-572-2728. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, lighting systems, etc. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 1910 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 604 Page 20052 Page 5052 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 11354 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 638 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Locations Drive Motor Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Locations Clockspring Assembly / Spiral Cable: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 12438 Junction Block - Left I/P X4 (except MEX) Page 15005 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 17607 Hood Stop: Service and Repair Hood Stop Bumper Bracket Replacement Hood Stop Bumper Bracket Replacement Page 16888 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 11908 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 1787 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 17095 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 11806 Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Passenger Compartment/Roof Component Views Driver Seat Components - 2 of 2 Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement (1500) Page 19390 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 12706 X129 Inline Harness Connector End Views X129 I/P Harness to Chassis Harness (HP2) Page 19801 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 11513 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral and Longitudinal Accelerometer Replacement Page 19429 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3019 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 5228 Camshaft Position (CMP) Sensor (Diesel) Page 2316 Disclaimer Page 18376 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair )Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Page 9795 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 1976 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Page 4522 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 2285 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 17896 Passenger Assist Handle: Service and Repair Roof Rail Rear Assist Handle Replacement Roof Rail Rear Assist Handle Replacement Page 2724 Junction Block - Left I/P X14 (5Y0/5X7/9L4) A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 14358 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Page 10303 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC/MYD/M99) Control Solenoid Valve Assembly X2 (MYC/MYD) Page 10076 Page 3743 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 2797 Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 7365 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13339 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 10792 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Page 16764 Disclaimer Page 16381 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 2190 Window Switch - Passenger (A31 without AN3/DL3) Locations Hybrid Battery Service Switch: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 13719 Page 3798 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 6920 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Initial Inspection and Diagnostic Overview Seat Heater: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Seats Begin the system diagnosis with theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . The Diagnostic System Check will provide the following information: * The identification of the control modules which command the system. * The ability of the control modules to communicate through the serial data circuit. * The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Page 14823 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 331 Page 766 Page 6137 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 6174 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Page 10985 9. Install the adjuster actuator lever (1) to the pivot pin on the primary brake shoe. 10. Install the brake shoe adjuster actuator lever spring (1). 11. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement) . Page 7396 Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Page 8791 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 4889 Page 8987 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Page 10626 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 8682 When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Page 10657 Page 7251 Harness Components Page 11598 10. Install the positive battery cable clips (2, 3, and 4) to the frame crossmember. 11. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 12. Lower the vehicle. 13. Install the positive battery cable lead (5) to the mega fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 14. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in) . 15. Install the auxiliary BEC cover (1). 16. Enable the high voltage system. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Page 15417 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 1900 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Electrical Specifications Fuel Injector: Electrical Specifications Resistance ........................................................................................................................................... ............................................................... 11-14 ohms. Page 11966 Warranty Information (Saab U.S. Models) Disclaimer Page 9318 Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Page 10526 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9713 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 2680 Fuse Block - Underhood Bottom View Page 15551 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended Cab with 10 Series with ASF) Page 11392 Electronic Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 13384 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 13299 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 20914 Washer Fluid Heater: Diagrams Component Connector End Views Windshield Washer Solvent Heater X1 (XA7) Windshield Washer Solvent Heater X2 (XA7) Page 19598 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Service and Repair Heater Hose: Service and Repair Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Page 7933 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7734 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Wiring Harness: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 17152 Page 18840 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Charging System - Volt Meter Fluctuation Information Charging System: Technical Service Bulletins Charging System - Volt Meter Fluctuation Information INFORMATION Bulletin No.: 07-06-03-009B Date: February 05, 2010 Subject: Information on Voltmeter Gauge Fluctuation Due to Regulated Voltage Control System and Concerns About Camper/Trailer Battery Charging Models: 2005-2010 Cadillac Escalade Models 2005-2010 Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2005-2010 GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 07-06-03-009A (Section 06 - Engine/Propulsion System). Voltmeter Fluctuation Condition Some customers may comment that the voltmeter is fluctuating between 12 and 14 volts on their full size pickup or utility vehicle. Starting with the 2005 model year, light duty full size pickups and utilities are equipped with a Regulated Voltage Control (RVC) system. This system reduces the targeted output of the generator to 12.6-13.1 volts when in "Fuel Economy Mode" to improve fuel economy. The generator may exit "Fuel Economy Mode" if additional voltage is required. This will cause the voltmeter to fluctuate between 12 and 14 volts as opposed to non-regulated systems that usually maintain a more consistent reading of 14 volts. This fluctuation with the RVC system is normal system operation and NO repairs should be attempted. Camper/Trailer Battery Charging Concerns Some customers may comment that when towing or hauling a camper/trailer, the auxiliary battery for the camper/trailer will not stay charged. In most cases, this concern is blamed on the new RVC system. While the RVC system does reduce the generator's targeted output voltage to 12.6-13.1 volts when in "Fuel Economy Mode", this feature is bypassed if the tow/haul feature is enabled. With the tow/haul feature enabled, the RVC system will stay in "Charge Mode" and the targeted generator output voltage will be 13.9-15.5 volts, depending on the battery state of charge and the estimated battery temperature. To keep the generator in the "Charge Mode", use either of the following two methods. - The first method is to use the tow/haul mode when towing or hauling a camper or trailer. - The second method is to turn on the headlights, which will increase the generator's targeted output voltage to 13.9-14.5 volts. Disclaimer Page 11480 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 15828 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 3460 The CMP actuator can be visually inspected to determine if the tension spring has returned the reluctor wheel and rotor to the park position. With the reluctor wheel returned to the proper parked position, the edge of the notched area of the wheel (2) aligns with the marking (1) on the camshaft sprocket. CMP Actuator Handling Safety Warning: Refer to Camshaft Position Actuator Removal and Installation Warning (See: Powertrain Management/Computers and Control Systems/Camshaft Position Sensor/Service Precautions) . Page 20652 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 7818 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 3670 Page 5410 Page 14883 Air Door Actuator / Motor: Service and Repair Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Page 443 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 1132 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Side Window Air Outlet Replacement Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Page 6658 Fuel Injector: Removal and Replacement Fuel Injector Replacement Removal Procedure Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. Note * An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. * The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 3. Remove the engine wiring harness bracket nut (1). OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 13769 Page 5901 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 4. Remove the HO2S (3). Installation Procedure Page 15304 Page 11272 1. Connect the right park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. Page 469 Page 13741 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 18490 Seat Horizontal Motor - Passenger (HP2) Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 18577 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 17857 Glove Compartment: Service and Repair Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Page 6221 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 10763 Wheel Speed Sensor (WSS) - Right Rear (JL4/HP2) Page 19627 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 12232 Junction Block - Left I/P X4 (except MEX) Page 8878 Page 12513 Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 1718 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Service and Repair Hydraulic System Junction Block: Service and Repair Brake Pipe Manifold Replacement Removal Procedure Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to service the HPA. Ensure that the recommended procedures are followed to relieve system pressure, including using the manual pressure release steps. Failure to properly follow procedures to depressurize the system may result in personal injury. Warning: Refer to Brake Fluid Irritant Warning. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution . Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Clean any dirt and debris from the brake modulator assembly and the brake pipe manifold. Note To ensure brake modulator and HPA pressure relief has occurred, the manual pressure relief valve must be opened momentarily. 4. Loosen the brake modulator manual pressure relief valve (1) 1/4 turn counterclockwise. 5. Seat, but do not tighten, the manual pressure relief valve. 6. Remove the brake pressure modulator valve assembly. Refer to Brake Pressure Modulator Valve Replacement . Page 6084 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Steering/Suspension - Ball Joint Availability Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Underhood Fuse Block Fuel Pump Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Page 10071 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) orTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 4. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver. Installation Procedure 1. Using the J 45756 , install a NEW front output shaft seal. 2. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) orTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 3. Check the fluid level. Add fluid, if necessary. 4. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . Page 9055 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 19593 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2679 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 11002 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Page 18800 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 2058 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 15589 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Under the Front Seats Components Page 12270 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 7490 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 19532 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 12019 Fuse Block - Auxiliary X3 (HP2) Page 11897 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 19948 Page 13804 Page 1147 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . Page 10343 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 14828 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 12347 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 420 Page 7331 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 20562 3. Observe the operation of the rear window defogger indicator while pressing the rear window defogger switch. The indicator should turn ON or OFF each time the rear window defogger switch is pressed. ‹› If the indicator does not turn ON or OFF with each switch press, replace the HVAC module. 4. Command the rear window defogger ON and OFF with a scan tool. The rear window defogger should turn ON and OFF when changing between the commanded states. Circuit/System Testing 1. Ignition OFF, disconnect the REAR DEFOG relay. 2. Test for less than 1 ohm between the ground circuit terminal 85 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify that a test lamp does not illuminate between the control circuit terminal 87 and ground. ‹› If the test lamp illuminates, test the control circuit for a short to voltage. 4. Verify that a test lamp illuminates between the B+ circuit terminal 30 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 5. Ignition OFF, disconnect the X2 harness connector at the defogger grid. 6. Test for less than 5 ohms between the defogger grid ground circuit terminal A and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 7. Connect the harness connector at the defogger grid. 8. Ignition ON, connect a 30A fused jumper wire between the B+ circuit terminal 30 and the control circuit terminal 87. Verify the defogger grid is activated. ‹› If the defogger grid does not activate, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the defogger grid. 9. Connect a test lamp between the control circuit terminal 86 and ground. 10. Command the defogger grid ON and OFF by pressing and depressing the rear defogger switch. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to voltage. If the circuit tests normal, replace the HVAC control module. ‹› If the test lamp is always OFF, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the HVAC control module. 11. If all circuits test normal, test or replace the REAR DEFOG relay. Component Testing Relay Test 1. Ignition OFF, disconnect the rear defog relay. 2. Test for 60-180 ohms between terminals 85 and 86. ‹› If not within the specified range, replace the relay. 3. Test for infinite resistance between the following terminals: * 30 and 86 * 30 and 87 * 30 and 85 * 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 30-amp fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohms between terminals 30 and 87. Page 3417 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange . 4. Tighten the lug nut until the stud contacts the back of the hub flange. Page 17120 5. Slide the trailer brake control module (1) toward the center of the vehicle and remove the trailer brake control module. Installation Procedure 1. If installing a new trailer brake control module, hand start the 3 trailer brake control module bolts. 2. Position the trailer brake control module to the frame bracket. 3. Slide the trailer brake control module (1) toward the left frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 2151 Page 13815 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Page 4743 Hybrid Battery Service Switch: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Component Locations Seat Position Sensor: Component Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 10652 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 8928 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Page 6968 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 13232 Junction Block - Left I/P X12 (except MEX) Page 10357 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5139 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Page 10815 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Page 20668 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 6482 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft). 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 15. Lower the vehicle. 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 19. Install the fuel fill cap. 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Page 8992 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 8318 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 18857 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 6610 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Page 7753 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 7770 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 15175 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2341 4. Tighten the air cleaner outlet duct clamp (1) at the MAF/IAT sensor. Tighten the clamps to 4 Nm (35 lb in). 5. Install the radiator inlet hose clamp clip (2) to the air cleaner outlet duct (1). 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 9278 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Diagrams Power Distribution Module: Diagrams Component Connector End Views Accessory DC Power Control Module X1 (HP2) Accessory DC Power Control Module X2 (HP2) Page 11716 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 10225 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 11091 23. Remove the BPMV assembly from the bracket (1). 24. Remove the sleeves and insulators from the BPMV, if necessary. 25. If replacing the BPMV, loosen but do not remove the EBCM bolts (1). Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 3074 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 8978 Harness Components Page 15146 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 4492 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Page 4679 23. Remove the sight shield circuit breaker fasteners (1). 24. Remove the sight shield circuit breaker (2). 25. Remove the APM ground strap fastener (2) and ground strap (1). 26. Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4). 27. Remove the ball studs (1) from the drive motor generator control module. 28. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 29. Lift the drive motor generator control module assembly from the vehicle. 30. To replace the drive motor generator power inverter module (PIM) assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation (See: Drive Motor Generator Power Inverter Module Removal and Installation) . To replace the accessory DC power control module, refer to Accessory DC Power Control Module Removal and Installation (See: Accessory DC Power Control Module Removal and Installation) . Installation Procedure Page 5786 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 11355 Trailer Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 16173 Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 6129 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 5243 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 19029 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 13070 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Duct Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Page 20075 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 20369 Page 7112 Page 13361 Page 8269 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 16668 Warranty Information (Saab U.S. Models) Disclaimer Page 7268 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: Customer Interest Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Page 14476 7. Install the lower shock absorber module mount bolts and tighten to 50 Nm (37 lb ft) . 8. Remove the support for the steering knuckle and upper control arm. 9. Install the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 10. Install the stabilizer shaft link to the lower control arm. Refer to Stabilizer Shaft Link Replacement (2500, 3500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair)Stabilizer Shaft Link Replacement (1500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair) . 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 12. Remove the support and lower the vehicle. 13. Align the front end. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) . Page 14714 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 442 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 7856 Harness Components Page 2131 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Page 4411 Generator Control Module Temperature Sensor (HP2) Page 10240 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16680 Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Page 13456 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 18892 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Heater Replacement Driver or Passenger Seat Cushion Heater Replacement Page 18294 2. Insert the end of the sunshade (1) to the driver side bracket (2) notch. 3. Insert the sunshade (1) to the passengers side bracket (2) notch. Page 20474 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2806 Page 12374 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 11833 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 13261 Page 14818 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 4254 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 4497 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 7848 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Page 12210 Fuse Block - Underhood X6 Page 7158 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 6923 1 - Fuel Injector 2 2 - Turbocharger Vane Position Sensor 3 - Fuel Injector 4 4 - Fuel Rail Pressure (FRP) Sensor 5 - Fuel Injector 6 6 - Fuel Injector 8 7 - Glow Plug 8 8 - Glow Plug 6 9 - Engine Oil Pressure (EOP) Sensor 10 - Engine Oil Level (EOL) Switch 11 - Glow Plug 4 12 - G106 13 - G102 14 - Glow Plug 2 Top of the Engine Components (Diesel) Page 5519 Data Link Connector: Diagrams Component Connector End Views Data Link Connector (DLC) Data Link Resistor Page 3788 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 4222 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 3063 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 14203 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair ). Page 13162 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Page 20181 Page 8828 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11674 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 16086 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Page 15315 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 12446 Junction Block - Left I/P X13 (AN3) Page 12476 Page 3987 13. Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 14. Remove the EN 46330 . Page 5798 High Speed Bus - 3 of 6 (Diesel) Page 10323 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12650 X300 Engine Harness to Chassis Harness (HP2) Page 5358 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 11652 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10761 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (Except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4/HP2) Page 7597 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 3422 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 15922 Disclaimer Page 2902 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 18527 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 8207 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 90 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 2735 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Underhood Fuse Block UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. Page 5428 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 10994 2. Turn the ignition key to the "OFF" position, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 4. Without the brake pedal applied, turn the ignition key to the "ON" position, with the engine OFF. 5. Using the Tech 2(R) scan tool, check the brake pedal travel using the steps below: 1. Select Diagnostics. 2. Build the appropriate vehicle information. 3. Select Chassis. 4. Select if the vehicle is equipped with Magnetic Ride Control Suspension Package (RPO Z95). 5. Select Electronic Brake Control Module (EBCM). 6. Select Data Display. 7. Under the Data List, scroll down the list and select "BMC Primary Piston Ref. Position" and "Master Cylinder Pressure Sensor" items as shown: Note First highlight the line and press the "Enter" soft key on the Tech 2(R) to get the "*" as shown for each item. - BMC Primary Piston Ref. Position - Master Cylinder Pressure Sensor - Then "Accept" the two selected items as shown on the top of the Tech 2(R) scan tool. 6. While observing the Master Cylinder Pressure Sensor on the scan tool data display, using moderate speed and moderate effort, depress the brake pedal to a force of 5,000 kPa (725 psi). 7. Record the distance displayed on the scan tool that the BMC Primary Piston has travelled at the applied brake pedal force of 5,000 kPa (725 psi). 8. Release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-8 to obtain a second measurement. Page 4939 Page 8305 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5835 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 5861 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (4.3L) Manifold Absolute Pressure (MAP) Sensor (Diesel) Page 16169 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ..................................................... 240 Nm (177 lb ft) OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 7145 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 9604 2. Using a pair of pliers, remove the retaining ring (2) from the yoke (1). 3. With the aide of an assistant, support the propeller shaft so that it level with the press. 4. Using the appropriate size socket (2), support the universal joint opposite of the J-9522-3 U-Joint Bearing Separator . 5. Using the J-9522-3 - Separator (1) and the press, remove the universal bearing from the yoke. 6. If you are unable to completely remove the universal bearing with the J-9522-3 - Separator , proceed to step 7. Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 7164 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19472 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 13375 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) Chassis Harness Routing (Except LY6/LMM/HP2) Page 17151 Page 11860 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7171 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6471 Evaporative Emissions Hose: Service and Repair Evaporative Emission Line Replacement Chassis Evaporative Emission Line Replacement - Chassis Evaporative Emission Hose/Pipe Replacement - Chassis Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (Without CH 48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 7825 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 18410 Page 12926 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 14058 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Page 2999 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 8113 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2946 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 17946 Center Pillar Lower Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Page 18476 Memory Seat Module (MSM) X6 (AN3) Page 12122 Page 18774 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4830 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 14773 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 8389 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 1677 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 19540 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11794 Page 18473 Memory Seat Module (MSM) X3 (AN3) Page 19444 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Underhood Fuse Block Fuel Pump Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Page 6222 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 5795 Low Speed Bus - 3 of 3 Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14082 Steering Control Module: Diagrams Component Connector End Views Electronic Power Steering Motor Control Module X1 (HP2) Electronic Power Steering Motor Control Module X3 (HP2) Page 11536 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Page 11889 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 17682 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4538 Note The gray side tabs on the accessory dc power control module (APM) assembly connector (2) must be pressed in before rotating the lever. 20. Disconnect the APM assembly connector (2) using the following procedure: 1. Push the green tab. 2. Squeeze the gray side tabs, then rotate the lever. 21. Disconnect the APM assembly connector (3) using the following procedure: 1. Remove the locking tab. 2. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector. 22. Disconnect the remaining APM assembly connector (1). Page 17945 Center Pillar Lower Garnish Molding Replacement Page 3284 Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 3445 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass and additional 90 degrees using J 45059 . 9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . Page 7409 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 11923 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 14219 5. Remove the idler arm bolts (3) and the nuts (1) at the vehicle frame. 6. Remove the idler arm (2) from the vehicle. Installation Procedure 1. Position the idler arm (2) to the vehicle frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the idler arm bolts (3) and nuts (1) to the frame and tighten to 105 Nm (78 lb ft) . 3. Install the idler arm (1) to the relay rod (2). Note Do not reuse the old idler arm nut. Page 19363 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 1495 Drive Motor Generator Battery Control Module X2 (HP2) Page 4035 Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 9256 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Procedures Brake Drum: Procedures Brake Drum Refinishing Special Tools * J 41013 Rotor/Drum Flange Resurfacing Kit * J 42450-A Hub Cleaning Kit Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions: * Brake system noise (squeal, growl, groan) * Uneven and/or premature brake lining wear * Superficial or cosmetic corrosion/rust of the brake drum surface * Scoring of the brake drum surface (less than the maximum allowable specification) 2. Brake drums should only be refinished if the following conditions exist: * Excessive corrosion/rust and/or pitting * Cracks and/or heat spots * Excessive blueing discoloration * Scoring of the brake drum surface (in excess of the maximum allowable specification) * Radial runout in excess of the maximum allowable specification 3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification: 1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. Refer to Brake Drum Diameter Measurement ( See: Testing and Inspection/Brake Drum Diameter Measurement) . 2. Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake Drum Surface and Wear Inspection (See: Testing and Inspection/Brake Drum Surface and Wear Inspection) . 4. If the brake drums can be refinished, proceed with the rotor refinishing procedure. 5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange. 6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions. 7. Ensure that any vibration dampening attachments are securely in place. 8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface. 9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe. 10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe. 11. Following the brake lathe manufacturer's instructions, refinish the brake drum. 12. After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter Measurement (See: Testing and Inspection/Brake Drum Diameter Measurement) . 13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced. 14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean the friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner and wipe the friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 15. Remove the brake drum from the brake lathe. Note Failure to clean the corrosion from the wheel bearing flange may result in increased lateral runout of the brake drum and brake system pulsation. Steering Shaft Upper Bearing Replacement Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement Steering Shaft Upper Bearing Replacement Special Tools * J 21854-01 Pivot Pin Remover * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter * J 42640 Steering Column Anti-Rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the steering column. Refer to Steering Column Replacement (Non-Hybrid) (See: Steering Column/Service and Repair/Steering Column Replacement)Steering Column Replacement (Two Mode Hybrid) (See: Steering Column/Service and Repair/Steering Column Replacement) . 2. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 3. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement) . 4. Remove the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Removal and Replacement/Ignition Lock Cylinder Case Replacement) . 5. Remove the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement) . 6. Remove the automatic transmission control. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement) . 7. Using compressorJ 23653-SIR and adapterJ 42137 , remove and discard the steering shaft lock plate retaining ring . 8. Remove the following parts from the steering column shaft assembly: 1. The turn signal switch cancel cam position plate (5) 2. The turn signal switch cancel cam (4) 3. The steering shaft upper bearing spring (3) 4. The steering shaft upper bearing inner race seat (2) 5. The steering shaft upper bearing inner race (1) Page 13477 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 5889 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 1193 Door Lock/Window Switch - Driver X4 (AN3) Page 16413 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 11760 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 18159 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Special Tools * J 41476 Front and Rear Cover Alignment Tool * J 41479-2A Crankshaft Rear Oil Seal Installation Guide Removal Procedure 1. Remove the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair) . 2. Remove the oil pan-to-rear oil seal housing bolts (1). 3. Remove the rear oil seal housing bolts (1). 4. Remove the rear oil seal housing (2) and gasket (3). Discard the gasket. 5. Remove and discard the rear oil seal (4). Installation Procedure Note * Do not reuse the crankshaft oil seal or rear cover gasket. * Do not apply any type of sealant to the rear cover gasket, unless specified. * The special tool in this procedure is used to properly center the crankshaft rear oil seal. * All gasket surfaces should be free of oil or other foreign material during assembly. * The crankshaft rear oil seal MUST be centered in relation to the crankshaft. * An improperly aligned rear cover may cause premature rear oil seal wear and/or engine assembly oil leaks. Page 4675 Drive Motor Control Module: Service and Repair Drive Motor Generator Control Module Assembly Replacement Drive Motor Generator Control Module Assembly Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 3. Disconnect the drive motor generator control module assembly connector (1). 4. Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . Page 3634 2. Install the valve rocker arm cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 lb in). 4. Install the PCV hose. Page 533 Page 12146 Page 11647 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 20741 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 2751 Page 12123 Junction Block - Right I/P X2 Page 1884 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 17738 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 3042 Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: All Technical Service Bulletins Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Page 12904 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 10221 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: Page 7449 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 20881 Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the GM Customer Assistance Center. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10153 Division Owner Letter Division Owner Letter Page 13022 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 8805 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 9035 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4523 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 13607 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 16250 Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 18697 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 19245 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Page 14917 Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 19941 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 7378 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 12111 Junction Block - Left I/P X7 (JF4) Page 6159 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 8813 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 10288 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 18205 Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 19940 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 4884 Page 7550 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 4286 Tighten the bolts to 9 Nm (80 lb in). 2. Clean the threads of the exhaust manifold bolts. 3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 4. Install a NEW catalytic converter seal to the exhaust manifold. 5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head. 6. Ensure that the catalytic converter seal is seated to the catalytic converter. 7. Install the exhaust manifold bolts. 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 20 Nm (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge. Page 12410 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6996 14. Disconnect the ignition coil wiring harness electrical connector (1) from the ignition coil. 15. Remove the spark plug wire from the ignition coil. * Twist the spark plug wire boot a 1/2 turn. * Pull only on the boot in order to remove the wire from the ignition coil. 16. Remove the ignition coil bolts. 17. Remove the ignition coil from the bracket. 18. There are 2 different manufacturers for the ignition coils and coil brackets. They are as follows: Page 11535 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Page 8153 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 18156 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Page 13685 Disclaimer Page 18659 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15490 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 6142 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 8154 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 7216 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 6043 Engine Control Module (ECM) X2 (4.3L) Page 15970 Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99/MEX) Page 2107 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 15027 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Page 7210 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 5348 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Interior - Sun Visor Fails to Stay In Up Position Sun Visor: Customer Interest Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Page 14168 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 18688 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 14253 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 7330 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 12517 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Page 12250 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 3122 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Page 7742 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 13366 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 13364 Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 8795 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 13724 X113 Engine Jumper Harness to Engine Harness (Diesel) Page 8267 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 14725 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 13474 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 555 Hazard Flasher Relay: Diagrams Component Connector End Views Emergency Vehicle Roof Lamp Relay (5Y0) Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Page 11505 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 12. Lower the vehicle. Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 20505 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7265 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 5342 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 20464 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 13513 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6431 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 1475 A/C Refrigerant Pressure Sensor (Diesel) A/C Refrigerant Pressure Sensor (Gas Except HP2) Page 5225 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Locations Air Door Actuator / Motor: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 20511 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17834 Front Floor Console Compartment Replacement (Except Cadillac) Front Floor Console Compartment Replacement (Except Cadillac) Page 8033 7. Remove the range selector lever nut (1). 8. Remove the range selector lever (2). Installation Procedure 1. Install the range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the range selector lever nut (1). Tighten the nut to 25 Nm (18 lb ft). Page 3731 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 6708 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 17944 Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Page 9305 Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Page 15393 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 4014 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Page 1981 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Page 7822 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 5420 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 13680 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 18304 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the full open position. 2. Release the switch. 3. Press and hold the open switch for 10 seconds or more. The glass panel will move further rearward of the open position, stall at the hard stop, and move back slightly to the soft stop or full open position. 4. Release the switch 5. Press and hold the open switch within 6 seconds. 6. Hold the open switch until the glass panel moves to the closed position and stops. 7. Release the switch. Page 12710 X175 Engine Harness to Transmission Internal Harness (M30) Page 17113 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 14475 9. Remove the lower control arm nuts (1) and washers (2). 10. Remove the control arm bolts (3). 11. Remove the control arm (4). Installation Procedure 1. Install the lower control arm (4). 2. Install the lower control arm bolts (3). 3. Install the washers (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the lower control arm retaining nuts (1) and tighten to 175 Nm (129 lb ft) . 5. Install the lower ball joint in the steering knuckle. 6. Install the NEW lower ball joint retaining nut and tighten to 125 Nm (92 lb ft) . Page 10471 Transfer Case Actuator: Locations Powertrain Component Views Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 16190 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 9336 In order to protect the differential case, install the following special tools on the opposite side of the differential case of the bearing being installed: * For the 8.6 inch axle , install the J 8107-4 - plug * For the 9.5/10.5 inch axles, install the J 36597 - pilot * For the 11.5 inch axle, install the J 8107-5 - plug Note Step 1, is for the 8.6 inch axle. 1. Using the J 8092 - driver (1),J 21784 - installer (2) and a hammer, install the differential side bearing. Note Step 2, is for the 9.5/10.5 inch axles. 2. Using the J 8092 - handle (1),J 29710 - installer (2) and a hammer, install the differential side bearing. Note Step 3, is for the 11.5 inch axle. 3. Using the J 8092 - handle (1)J 44420 - installer (2) and a hammer, install the differential side bearing. 4. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . Page 16046 Page 15883 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18493 Seat Rear Vertical Motor - Driver (HP2) Seat Rear Vertical Motor - Passenger (HP2) Page 19158 11. Reinstall the foam (1) to the latch rod. 12. Reinstall the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 13. Reinstall the right endgate latch. Refer to Endgate Latch Replacement in SI. 14. Reinstall the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14319 Electronic Power Steering Motor Control Module X4 (HP2) Page 9461 7. Using the J 2222-C - wrench , and loosen the adjusting nut. 8. Remove the adjusting nut. Note If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 11. Using a suitable seal removal tool, remove the oil seal from the wheel hub. Page 13764 Multiple Junction Connector: Diagrams X300 - X399 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) X300 Chassis Harness to Engine Harness (4.3L) Page 18846 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 1591 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 4741 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 5873 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 7290 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 11935 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 13286 Fuse: Application and ID Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Locations Seat Memory Switch: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 09-08-127-001 - END OF INFORMATION NEED Parking Assist Distance Sensor: All Technical Service Bulletins 09-08-127-001 - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-127-001B Date: August 10, 2009 Subject: EI09084 - Rear Parking Assist System Inoperative (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2009 Saturn OUTLOOK All Equipped with Rear Parking Assist (RPO UD7) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-127-001A (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 8657 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 20589 Door Lock/Window Switch - Driver X3 (AN3/DL3) Page 12454 Page 13079 Branching Point: Diagrams JX339 Splice Pack Connector End Views JX339 (Except MEX) Page 9721 Page 17363 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 20232 Camshaft Position Actuator Magnet Replacement Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Magnet Replacement Camshaft Position Actuator Magnet Replacement Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement. 2. Disconnect the engine harness electrical connector from the camshaft position (CMP) actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note The gasket surface should be free of oil or other foreign material during assembly. Page 13857 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 352 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7177 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 696 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 13629 Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 17952 Page 10338 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13832 Page 15385 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 6467 2. Position and connect the EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Install the EVAP rear pipe to the fuel tank clips (1 and 2). 4. Install the EVAP canister purge pipe to the fuel tank clip (1). 5. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 12354 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 5077 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 8815 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 20867 the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers/retailers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Note (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by June 8, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Note Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for the recall condition are handled by submitting a recall reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - submit as Net Item under the repair labor code. Page 14658 Customer TPMS Information Page 10213 View of the connector when released from the component. View of another type of Micro 64 connector. Page 18108 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Locations Audible Warning Device Control Module: Locations Instrument Panel/Center Console Component Views Inside the I/P Components (UL5) 1 - Chime Module Page 12944 Page 6057 Page 7892 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 9174 Disclaimer Page 8263 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 12192 Page 11756 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 18837 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 20751 1 - X415 2 - J412 3 - J419 4 - Right Hip Lamp Harness 5 - Left Hip Lamp Harness 6 - J418 7 - J413 8 - X416 Page 17423 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2870 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Page 8800 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 4259 Thermostat: Service and Repair Engine Coolant Thermostat Replacement Removal Procedure 1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LY2, LH6, LY5, LMG, LY6) () . 2. Remove the thermostat. Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LY2, LH6, LY5, LMG, LY6) () . Page 19199 For vehicles repaired under warranty, use the table. Disclaimer Page 9130 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 1468 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12299 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 12684 X109 Inline Harness Connector End Views X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (Except NQF/NQH/HP2/Late Production with 4.8L/5.3L/6.0L/6.2L) Drivetrain - Clunk Noise At A Stop Or From Launch Slip Yoke: All Technical Service Bulletins Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 11594 11. Install the underhood junction block cover. 12. Connect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair )Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . Page 13858 Page 5285 Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 12707 X150 Inline Harness Connector End Views X150 Engine Harness to I/P Harness (HP2) Page 4465 Hybrid Battery Service Switch: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 7804 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 11902 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 6773 11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line. 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 16. Remove the fuel line bracket bolt (1). 17. Remove the fuel/EVAP line clip nut (2). 18. Remove the fuel/EVAP line clips from the frame and crossmember. 19. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 1654 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor Replacement Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Page 13628 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Page 7872 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 15702 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab with 10 Series with ASF) Page 13475 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 10033 Page 3118 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 18373 Disclaimer Page 15415 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 16346 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 12416 Page 1866 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 16330 Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Average Fuel Economy (AFE) * Average Speed (AVS) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/Active Fuel Management (Displacement on Demand (DOD)) * Odometer * Trans Temp * Trip Odometer * Trip Time * Total Fuel Saved (Hybrid) * Fuel Saved Since Reset * Compass * Outside Air Temperature * Blank Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu * Engine Hours * Compass * Outside Air Temperature * Side Obstacle Detection Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language Lighting - Dome/Reading Lamps Inoperative Map Lamp: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 18776 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 3052 Junction Block - Left I/P X13 (AN3) Page 9094 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 10494 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 18494 Seat Recline Motor - Driver (AN3) Page 7254 Component Parts Page 10794 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter . 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed Procedure (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2783 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 5116 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 17633 Body Emblem: Service and Repair Hood Emblem/Nameplate Replacement (Vortec) Hood Emblem/Nameplate Replacement (Vortec) Page 14545 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Page 18953 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in) . 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 11044 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Interior - Wear Spots On Vinyl/Rubber Floor Covering Carpet: All Technical Service Bulletins Interior - Wear Spots On Vinyl/Rubber Floor Covering TECHNICAL Bulletin No.: 08-08-110-013 Date: August 18, 2008 Subject: Premature Wear or Worn Spots on Rubber/Vinyl Floor Covering (Replace Floor Covering) Models: 2007-2009 Chevrolet Silverado, Silverado HD, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra HD, Yukon, Yukon XL with Rubber Floor Covering (RPO BG9) Including Police (RPO PPV) and Municipal (RPO 5W4) Vehicles EXCLUDING Standard and Crew Cab Models Condition Some customers may comment on premature wear or worn spots (1) on the front rubber/vinyl floor covering. Correction Important: The standard and crew cab models already have the updated floor mat material. Replace the affected floor covering. Refer to Floor Panel Carpet Replacement in SI. The mat floor covering material has been updated to reduce premature wear. Parts Information Page 15314 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 3939 1. Lubricate the outer edge of the oil seal (140) with clean engine oil. 2. Lubricate the front cover oil seal bore with clean engine oil. 3. Install the crankshaft front oil seal (140) onto the J 41478 guide. 4. Install the J 41478 threaded rod (with nut, washer, guide, and oil seal) into the end of the crankshaft. 5. Use the J 41478 in order to install the oil seal into the cover bore. 1. Use a wrench and hold the hex on the installer bolt. 2. Use a second wrench and rotate the installer nut clockwise until the seal bottoms in the cover bore. 3. Remove the J 41478 . 4. Inspect the oil seal for proper installation. The oil seal should be installed evenly and completely into the front cover bore. 6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair) . Page 7938 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Locations Air Bag Deactivation Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 18094 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 4471 Drive Motor Generator Battery Control Module X3 (HP2) Page 1798 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor (1). 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 4562 Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 14186 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Navigation Radio - Weak Or No GPS Signal Information Global Positioning System: All Technical Service Bulletins Navigation Radio - Weak Or No GPS Signal Information INFORMATION Bulletin No.: 08-08-44-027 Date: August 12, 2008 Subject: Information on Navigation Radios that Have a Weak or No GPS Signal Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models with Navigation Radios Some customers may comment on intermittent or no Global Positioning System (GPS) signal reception on the Navigation radio. The GPS signal reception icon on the map screen may have a red line through it. This condition may be caused by aftermarket electronic devices such as radar detectors, cell phones, and MP3 players that may interfere with the GPS signal reception. Aftermarket window tinting or clear UV film applied to the windshield may also reduce the GPS signal reception and cause the Navigation radio to function incorrectly. Recommendations Educate the customer on the GPS antenna location and the need to keep electronic devices away from it. The GPS antenna is located in the upper center of the Instrument Panel. Instruct the customer to move electronic devices away from the GPS antenna. It may also be necessary to remove aftermarket films and tinting from the windshield. Do not replace a Navigation radio that seems to have poor GPS signal reception without considering these possible causes of the concern. Refer to the No Global Positioning System (GPS) Reception diagnostic procedure in SI for more information. Disclaimer Page 1376 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 7899 View of the connector when released from the component. View of another type of Micro 64 connector. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Diagrams Sun Shade: Diagrams Component Connector End Views Sunshade - Left (DH6) Sunshade - Right (DH6) Page 3209 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 313 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 13452 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 20197 Page 8595 Director, Customer and Relationship Services 09241 Page 417 Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 13442 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Page 6171 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 14261 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 1544 Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump (Diesel with 31 Series without NQZ) Fuel Pump and Sender Assembly - Front (Gas Except MEX) Page 487 Page 11181 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 5548 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 20644 Power Window Switch: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 9875 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 13385 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 10911 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 5764 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 804 Page 12577 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 9473 1. Install the disc brake axle shaft (1) in the rear axle assembly (2), if equipped. 2. Install the drum brake axle shaft (2) in the rear axle assembly (2), if equipped. Page 7808 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12488 Fuse Block - I/P X3 Page 15396 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 7188 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2197 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 5460 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 15543 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 - X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) Page 8786 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 10320 Devices and Sensors Page 18327 Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Extended Cab) Sunroof Air Deflector Replacement (Extended Cab) Removal Procedure 1. Open the power sunroof window to the fully rear position. 2. Remove the actuators screws (1) and actuators (2) from each side of the sunroof module. 3. Remove the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). 4. Slide the air deflector rearward until it releases from the sunroof module. 5. Remove the sunroof air deflector (2) from the sunroof module (3). Installation Procedure OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 8270 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 8784 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 270 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Page 10169 Module Circuit Function Icons Page 17572 1. Install the regulator (1) and cables (2) to vehicle. 2. Install the cable ends (1) to the window guide (2) at each end of the window. Page 9045 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 10948 - Brake rotor discard thickness 28.50 mm (1.122 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JD9, JF3, JF7))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JH6, JH7)) and/orRear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JH6, JH7)) . 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Calculate the difference between the highest and lowest thickness measurement recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the following specifications: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in) Brake rotor maximum allowable thickness variation: 0.009 mm (0.0004 in) Note Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Page 5084 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 2222 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 19461 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 12312 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12491 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 7778 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 17862 Instrument Panel Compartment Door Lock Cylinder Replacement Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Remove the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: )Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: ) . 2. Position the instrument panel compartment latch fork bolt in the up position. 3. Insert the key into the instrument panel compartment lock cylinder. 4. Rotate the instrument panel compartment lock cylinder clockwise to the 3 o'clock position with the key. 5. With the key in position, apply a light load and depress the retainer tumbler through the poke hole at the right hand side of the instrument panel compartment latch. Page 12091 Page 13776 Page 11565 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in) . 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in) . 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery Cable/Service and Repair) . Page 1145 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Page 20648 Door Lock/Window Switch - Driver X4 (AN3) Diagrams Rear Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (Except AU3) Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Engine - Oil Consumption On Aluminum Block Engines Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 7828 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 7224 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 4619 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 17858 Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 6541 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 13316 Page 3062 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 9048 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 10153B Date: 100720 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 10153B Date: July 20, 2010 Subject: 10153A - Heated Windshield Washer Module Short Circuit - Permanently Disable and Remove Module Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2009 HUMMER H2 2007-2009 Saturn OUTLOOK Equipped with Heated Washer Fluid System (RPO XA7/CHW) Supercede: This bulletin is being revised to include a note in the service procedure for dealers to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. A T labor code for customers who refuse to have the recall performed. This labor code will NOT close the recall. If a customer refuses to have the recall performed, dealers are to provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. Request that the letter be placed in the vehicle glovebox for future reference by subsequent owners. If at a later date the customer, or a new owner, decides to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. A clarification in the Q&A; regarding proof of vehicle ownership. Please discard all copies of bulletin 10153A, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW). A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. Correction Dealers/retailers are to permanently disable and remove the heated washer fluid system and compensate the customer for the loss of the feature. Vehicles Involved Involved are certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW), and built within these VIN breakpoints: Page 12855 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 12932 Switch Position Icons Page 19946 Page 13472 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 10029 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) Page 15024 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Hybrid - Reinstalling Hybrid Transmission Drive Motors Wiring Harness: All Technical Service Bulletins Hybrid - Reinstalling Hybrid Transmission Drive Motors INFORMATION Bulletin No.: 10-06-122-001 Date: November 03, 2010 Subject: Reinstalling Hybrid Transmission Drive Motors On 2-Mode Hybrid Full Size Trucks Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with 2ML70 Hybrid Transmission (RPO M99) All Built Prior to VIN Breakpoint 10020698 During service of a 2-Mode hybrid drive motor, the motor harness can easily be damaged if the appropriate precautions are not used. When reinstalling a drive motor, sharp edges of the transmission case access opening may chafe or cut the harness when the drive motor is fed through the case opening. Recommendation Use the procedure and parts below to protect the drive motor harness PRIOR to reinstallation into the transmission case. 1. Remove the black plastic wiring harness clip (1) from the motor casing and pull the harness out of the clip, exposing the drive motor wires (2). Page 16613 Page 18669 Front Seat Cushion Inner Trim Panel Replacement Front Seat Cushion Inner Trim Panel Replacement Page 5009 Camshaft Position (CMP) Sensor (Diesel) Page 868 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 15994 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 8803 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15865 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 5011 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 6700 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Transmission 5 Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 X175 (MW7) Page 20779 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Page 17947 Jack Stowage Cover Replacement Jack Stowage Cover Replacement Page 2829 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 18759 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7859 Component Parts Page 7982 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 7926 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 1802 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 15660 Disclaimer Page 1322 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Page 7687 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 7775 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 11854 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 8047 Harness Components Page 11010 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Page 19624 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 5879 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 15444 * Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt pretensioner on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Sensor Replacement Guidelines The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. * Replace the sensor whether or not the air bags have deployed. * Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6835 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 6218 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 13721 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (4.8L, 5.3L, 6.0L and 6.2L) Page 19354 Switches and Relays Page 3022 Page 15885 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 6234 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 20937 Page 17325 Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (without SLT) Front Side Door Inside Handle Replacement (without SLT) Page 20788 8. Install the rear sliding window stops (1) in place and fully seated. 9. Cycle the rear sliding window to the fully closed position. 10. Install the lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 11. Inspect the rear sliding window for proper operation. 12. Clean the window. Page 11026 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 8107 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1964 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Front of Vehicle/Engine Compartment Component Views Front of the Vehicle Components (except 10 Series) Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 752 Engine Control Module (ECM) X3 (HP2) Page 8506 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Pipe Replacement Transmission Fluid Cooler Pipe Replacement Page 7529 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Page 5369 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 1125 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 5635 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 2810 Fuse Block - Underhood X3 Page 13746 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (Except TZ0) Page 6293 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 8244 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 10425 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 13799 Page 10907 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 17106 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 4202 Page 10173 Component Parts Page 10146 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Page 11406 4. Remove the ABS module splash shield bolts (1). 5. Remove the ABS module splash shield (1). Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 12375 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 8994 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 13088 Warranty Information (Saab U.S. Models) Disclaimer Page 13188 Page 2573 5. Select Special Functions 6. Select Automated Bleed 11. Press Start to begin the automated bleed procedure. Ensure the J-29532-A orJ 29532 has not yet been installed to the vehicle. The travel and pressure sensors are being calibrated and learned by the EBCM during this step. 12. Press Start to continue. Note Approximately 2.5-3.0 L (2.6-3.2 qt) of brake fluid will be used throughout this procedure. Ensure there is an adequate supply of brake fluid in the J-29532-A orJ 29532 . 13. Inspect the fluid level in the J-29532-A orJ 29532 . Clean the outside of the J-29532-A orJ 29532 and add GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container, as necessary. 14. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Note Do not pressurize the J-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. 15. Install the J 35589-A and the J-29532-A orJ 29532 to the vehicle. Note Ensure a MINIMUM of 200 kPa (30 psi) of pressure is MAINTAINED in the J-29532-A orJ 29532 throughout this procedure, except as instructed. 16. Set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). 17. Open the J-29532-A orJ 29532 fluid tank valve to allow pressurized brake fluid to enter the brake system. 18. Wait approximately 30 seconds, then inspect the entire hydraulic brake system to ensure there are no existing external brake fluid leaks. 19. Secure bleeder hoses to all 4 brake caliper bleeder valves. 20. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 21. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 22. Press Start to begin the system automated bleed steps. Follow all instructions on the scan tool. Only apply the brake pedal when instructed to do so by the scan tool. 23. When instructed, firmly apply and release the brake pedal using smooth, consistent full brake pedal strokes. The brake pedal will go fully to the floor with some pedal feedback felt. The master cylinder reservoir supply circuit is being flushed through these steps. 24. Continue the brake applications until instructed by the scan tool. The scan tool will instruct to perform 10 brake applies. 25. When instructed by the scan tool, stop performing the brake applications and press Enter. The scan tool will instruct to perform Steps 23-25 2 more times. 26. When instructed by the scan tool, press Start to continue. Note The hydraulic brake system will be under high pressure during the next bleed sequence. Ensure the bleeder hose is maintained securely to the bleeder valve, and open the bleeder valve slowly. 27. Following the instructions on the scan tool, open the left rear (LR) brake caliper bleeder valve. 28. With the bleeder valve open and the bleeder hose maintained firmly in place, press Start to begin the bleeding process. This process will run in a 30-second cycle. The pump and HPA circuits are being flushed during these steps. 29. Press Enter when instructed to repeat the bleeding process 5 more times on the scan tool. 30. Press Enter when instructed at the end of the 6th bleeding process. 31. Ensure the LR brake caliper bleeder valve is tightened securely. 32. Reduce the charge in the air tank of the J-29532-A orJ 29532 to 0 kPa (0 psi). 33. Press Start to continue. The brake pedal simulator circuit is being flushed through this step. 34. Place shop cloths beneath the master cylinder brake pipe connections to protect the vehicle from the brake fluid expelled during the next sequence. 35. When instructed by the scan tool, set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement (1500) Page 12413 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10336 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 6528 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 5427 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 845 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 13623 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Page 11593 7. Remove the auxiliary battery positive cable terminal from the underhood junction block stud. 8. Reposition the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 9. Remove the auxiliary battery positive cable nut (6) from the rely stud. 10. Remove the auxiliary battery positive cable terminal from the relay stud. 11. Remove the auxiliary battery positive cable clips (4) from the engine wiring harness and remove the cable from the vehicle. Installation Procedure 1. Install the auxiliary battery positive cable to the vehicle. 2. Install the auxiliary battery positive cable terminal to the relay stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the auxiliary battery positive cable nut (6) to the rely stud and tighten to 7.5 Nm (66 lb in) . 4. Position the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 5. Install the auxiliary battery positive cable to the battery positive post. 6. Tighten the auxiliary battery positive cable nut (2) and tighten to 7.5 Nm (66 lb in) . 7. Install the auxiliary battery positive cable terminal to the underhood junction block stud. 8. Install the auxiliary battery positive cable nut (1) to the underhood junction block stud and tighten to 5 Nm (44 lb in) . 9. Install the auxiliary battery positive cable clips (4) to the engine wiring harness. 10. Close the auxiliary battery positive cable post cover. Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 8776 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 9100 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 1051 Page 13054 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 7080 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Specifications) . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 2334 8. Rotate the balancer (1) and additional 360 degrees to ensure proper belt installation. 9. Install the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 10. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory) . Page 6666 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 14. Install the PCV hose. 15. Gather the branches of the engine wiring harness and position over the top of the engine. Page 3075 Fuse Block - Underhood Bottom View Locations Hybrid Power Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 20494 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 730 Engine Control Module (ECM) X1 (Diesel) Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 5058 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 11067 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Page 8840 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 7917 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 8781 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Hood Bumper Replacement Hood Stop: Service and Repair Hood Bumper Replacement Hood Bumper Replacement Page 20557 Page 8931 Shift Cable: Service and Repair Range Selector Lever Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Remove the driver seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket) . 4. Remove the body hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 5. Pull back the carpet and insulation around the driver area. 6. Remove the retainer securing the cable to the steering column. Page 581 Page 12034 Page 6839 Fuel Pump and Sender Assembly - Rear (LY6 with MEX without NQZ) Page 13258 Fuse Block - I/P X2 (except MEX) Page 5950 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Body Control Module (BCM) X2 Page 12449 Junction Block - Right I/P (Wire Entry) Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Page 7169 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 1352 Front Axle (NP8) 1 - Frame 2 - X110 (NQF/NQG/NQH/NP2) 3 - Front Axle Housing 4 - Front Drive Axle Actuator (NQF/NQG/NQH) Page 12578 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Diagrams Discharge Air Temperature Sensor / Switch: Diagrams Component Connector End Views Inside Air Temperature Sensor (CJ2) Page 16652 Audio Amplifier X2 (UQA) Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 7213 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 3697 Fender/Front Fender Liner/Service and Repair) . 9. If the vehicle is equipped with 4WD, install the front drive axle. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . Page 8879 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC/MYD/M99) Control Solenoid Valve Assembly X2 (MYC/MYD) Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 11523 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 13259 Fuse Block - I/P X3 Page 17301 For vehicles repaired under warranty, use the table above. Disclaimer Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 2575 44. If the primary brake pipe port (1) was not fully bled within the 60-second cycle time, press Start to repeat Steps 42-43. 45. Press Enter to continue. 46. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 47. Open the right rear (RR) brake caliper bleeder valve. Ensure the RR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 48. If the RR bleeder valve was not fully bled within the 60 second cycle time, press Start to repeat Step 47 until the brake fluid is clear of any air. 49. Press Enter to continue. 50. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 51. Open the left rear (LR) brake caliper bleeder valve. Ensure the LR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 52. If the LR bleeder valve was not fully bled within the 60-second cycle time, press Start to repeat Step 51 until the brake fluid is clear of any air. 53. Press Enter to continue. 54. Secure bleeder hoses to all 4 brake caliper bleeder valves. 55. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 , in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 56. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 57. Press Enter to continue. 58. Remove the J 35589-A and the J-29532-A orJ 29532 from the vehicle. Note The system is active and pressurized, therefore the brake fluid level in the master cylinder reservoir cannot be allowed to be higher than the MAX mark of the operating range. 59. Ensure the master cylinder reservoir is filled no higher than the MAX operating range line. Add or remove brake fluid as necessary. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 60. Start the engine. 61. Press Start to continue the final sequence. The pump and the HPA circuits are being flushed, and the boost valve is being calibrated and learned by the EBCM through this step. 62. Continue to follow the instructions on the scan tool. 63. Allow the engine to idle for 1 minute to allow the system to recalibrate. 64. Turn the engine OFF, then turn the ignition switch to the ON position without starting the engine. 65. Clear any DTCs from the EBCM. 66. The hybrid brake control modulator is an OBDII compliant module. As such, brake related DTCs may be stored in the powertrain control modules. After addressing any other stored DTCs, clear any brake related DTCs stored in the powertrain control modules. 67. Turn the ignition switch to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 68. Allow the vehicle to remain OFF for at least 1 minute before applying the brake pedal, starting the engine, or performing a test drive. This waiting period is essential to complete the sensor and boost valve calibration and EBCM learn processes, and to allow the HPA to depressurize to allow for a deactivated system pedal feel check. 69. Remove the scan tool from the vehicle. 70. Before starting the engine, firmly apply the brake pedal several times. Observe the brake pedal feel. 71. If the brake pedal feels spongy, perform the following: 1. Repeat the base hydraulic brake system bleeding procedure. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Brakes and Traction Control/Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . 2. If the brake pedal feel is now firm, repeat the automated bleeding procedure. 3. If the brake pedal stills feels spongy after repeating the base hydraulic brake system bleeding procedure, inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 72. If the brake pedal stills feels spongy, an if no external brake fluid leaks are found, inspect the brake system for internal leaks and inspect the brake pedal travel. Refer to Brake System Internal Leak Test (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System Internal Leak Test)Brake System Internal Leak Test (Non-Hybrid) (See: Page 2377 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Tune-up and Engine Performance Checks/Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 13216 The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Fuse 11 ................................................................................................................. ...................................................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 4640 Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 22. Clean the sealing surface of the 3 phase cable cover as necessary. 23. Position the 3 phase cable cover (2) onto the PIM distribution box ensuring the seal remains in place. 24. Tighten the 3 phase cable cover fasteners (1). Tighten the fasteners to 9 Nm (80 lb in) . 25. Connect the drive motor generator control module assembly connector (1). 26. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . 27. Install the sight shield. Refer to Drive Motor Generator Control Module Sight Shield Replacement (See: Drive Motor Generator Control Module Sight Shield Replacement) . 28. Install the fender cross brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 29. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . 30. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 31. For control module programming and setup procedures, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 17574 1. Align the tabs (2) on the pulley (1) with the notch in the frame (3). 2. Turn the pulley downward, locking the pulley into the frame (3). 6. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame. 7. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place. Page 5883 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Page 18824 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 10245 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 424 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings) . Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Place the ignition switch in the OFF position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the antilock brake system (ABS) module splash shield retainer (1). Page 10982 1. Compress the park brake cable spring and insert the park brake cable fitting end to the park brake on the secondary brake shoe (1). Position the secondary brake shoe to the rear brake backing plate. 2. Install the brake shoe return spring. Insert the hook end of the return spring to the brake shoe from behind the web. Page 19137 6. Using a suitable tool, at the center of the rod, bend one leg of the rod towards the center as shown (1). The object is to make one end of the "U" shaped section of the rod close to a 90 degree bend. Take care not the twist the rod as you bend it. 7. Using the same tool, straighten the rod at the other bend shown (1) until the rod is back straight. Take care not to twist the rod as you bend it. 8. Inspect the rod standing up on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 9. Inspect the rod laying flat on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 10. Inspect the overall length of the rod as shown. The overall length of the rod should be 3-4 mm (0.118-0.157 in) shorter. If the length is not correct, rebend the rod using the steps above to achieve the correct length. Page 12297 Sunroof Air Deflector Replacement (Crew Cab) Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Crew Cab) Sunroof Air Deflector Replacement (Crew Cab) Page 3051 Junction Block - Left I/P X12 (except MEX) Page 13439 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 19373 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 1219 For vehicles repaired under warranty, use the table. Disclaimer Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Page 15111 Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 19460 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 10594 Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 11066 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. Page 8768 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 11396 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Page 19161 Tailgate Release Handle: Service and Repair Endgate Handle Replacement Endgate Handle Replacement Page 13581 Page 7499 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Page 13184 Page 11004 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter . 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed Procedure (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Page 748 Page 7010 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 11761 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15613 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 11145 10. Remove the brake pushrod retainer (1). 11. Slide the stoplamp switch (1) off of the brake pedal pushrod pin while simultaneously disconnecting the brake pushrod. Page 7783 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 5937 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 7548 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 9118 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 20892 Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. "An unattended (vehicle parked - key not in the "ON" position) under hood fire that can occur at any time and possibly involve nearby vehicles or structures." If the customer still refuses, provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record "customer declined recall repair" on the repair order and, if possible, have the customer sign the repair order. Retain this repair order at the dealership. Page 18162 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Endgate Latch Replacement Tailgate Latch: Service and Repair Endgate Latch Replacement Endgate Latch Replacement Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axle) Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axle) Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axle) Special Tools * DT 47688 - Pinion Bearing Remover * J 7818 - Inner Bearing race Installer * J 8092 - Universal Driver Handle 3/4-10 * J 8611-01 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22306 - Bearing Race Installer * J 22828 - Input Shaft Gear Installer * J 22912 - Bearing Remover * J 36614 - Inner Pinion Bearing Installer * J 45870 - Inner Pinion Bearing Race Installer Disassemble Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 3. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles))Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) (See: Pinion Gear/Service and Repair/Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)) . Note Step 4 is for those vehicles equipped with the 8.6 inch axle. 4. Using theDT 47688 - remover and a press, remove the bearing from the drive pinion. Page 1286 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 4167 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 lb in). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor (2). Tighten the clamp to 4 Nm (35 lb in). Page 9054 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 3900 32. Remove the manifold absolute pressure (MAP) sensor retainer. 33. Remove the MAP sensor and discard the MAP sensor seal. 34. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 35. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 36. Remove the EVAP tube and purge solenoid. Page 3107 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 13782 X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 12477 Fuse Block - Underhood X4 Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 20574 Page 17814 Carpet: Service and Repair Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 88861431 (Canadian P/N 88861436), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 11024 Page 15174 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 12730 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Page 19448 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 506 Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 2873 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Instrument Panel/Center Console Component Views Behind the I/P Components Page 15035 Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch (C67) A/C Compressor Clutch (CJ2) 08-08-49-016C - END OF INFORMATION NEED Fuel Gauge Sender: Technical Service Bulletins 08-08-49-016C - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 08-08-49-016C Date: May 21, 2009 Subject: EI08347 - DTC P0463, Fuel Gauge/Gage Inaccurately Reads Empty, Low Fuel Light On (Diagnose and Repair Using SI) Models: 2008-2009 Buick Lucerne 2008-2009 Chevrolet Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 08-08-49-016B (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. This bulletin is being revised to end the need for dealer feedback. If you encounter a vehicle with this concern, please diagnose and repair using the information found in SI. Disclaimer Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 15907 Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Replacement - Front Seat Belt Height Adjuster Replacement - Front Page 19665 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 6147 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 10980 7. Remove the lower brake shoe spring (1). 8. Rotate the primary brake shoe (1) outward, disengage the return spring from the brake shoe web and remove the primary brake shoe. Page 19921 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 7047 Crankshaft Position (CKP) Sensor (Diesel) Page 5150 3. Connect the engine wiring harness electrical connector (7) to the HO2S. 4. Install the engine wiring harness electrical connector clip (6) to the fuel line clip. 5. Install the CPA retainer (4). 6. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Lower the vehicle. Locations Auxiliary Power Outlet: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 8150 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 2718 Junction Block - Left I/P X8 (except MEX) Page 3443 4. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Page 11754 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 8106 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2844 Junction Block - Left I/P X11 (except MEX) Page 7223 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 16060 Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Mobile Telephone Digital Antenna Replacement Page 6992 Ignition Coil 8 (4.8L/5.3L/6.0L/6.2L) Page 11919 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 14546 Disclaimer Page 10263 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 2726 Junction Block - Right I/P (Wire Entry) Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 10352 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 12915 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 13706 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 9284 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Page 9975 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Page 9470 8. Remove the differential pinion gear shaft. Note Rotate the differential case until the differential pinion shaft just touches the rear axle housing. 9. Remove the differential pinion gear shaft part way from the differential case. 10. Use a screw driver, or similar tool to rotate the lock (1) until the lock (1) aligns with the thrust block (2). Page 5013 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 6529 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Page 19394 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 7299 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 19157 6. Using a suitable tool, at the center of the rod, bend one leg of the rod towards the center as shown (1). The object is to make one end of the "U" shaped section of the rod close to a 90 degree bend. Take care not the twist the rod as you bend it. 7. Using the same tool, straighten the rod at the other bend shown (1) until the rod is back straight. Take care not to twist the rod as you bend it. 8. Inspect the rod standing up on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 9. Inspect the rod laying flat on a flat surface as shown. The rod should rest flat on the surface. Minor gapping (1) on the bent leg is acceptable. 10. Inspect the overall length of the rod as shown. The overall length of the rod should be 3-4 mm (0.118-0.157 in) shorter. If the length is not correct, rebend the rod using the steps above to achieve the correct length. Page 557 Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Page 9522 12. Remove the inner hub bearing. 13. Using a brass drift and a hammer, remove the inner hub bearing cup. 14. Remove the retaining ring from the wheel hub. 15. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Page 7202 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 13924 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 17108 Trailer Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 1362 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer . 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 12248 Page 7068 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 13050 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 12718 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (Except TZ0) Page 6195 Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 6134 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 12752 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Page 5754 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 17719 Page 732 Page 7835 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 3351 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 1961 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 19827 Page 7942 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12635 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (HP2/Late Production except Y91/MEX/8S8) OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 454 4. Tighten the trailer brake control module bolts (1) to 9 Nm (80 lb in) . 5. Connect the trailer brake control module electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 7. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 18726 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 8366 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 14520 Note The inboard strut mounting studs are spaced closer together than the outboard stud. The outboard stud should be facing toward the outside (closest to the technician proper alignment. 1. Assemble the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) in the spring compressor. 2. Align the spring seat stop (3), the outboard stud (1), and the center of the lower strut mount (4). The notch in the spring seat (2) should be just to the right of the outboard stud. Page 1476 A/C Refrigerant Pressure Sensor (HP2) Page 1300 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Page 6432 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Steering/Suspension - Power Steering Fluid Leaking Steering Rack Gear: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 7814 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 11590 11. Connect the auxiliary battery positive cable electrical connector (2) to the engine wiring harness connector. 12. Install the relay (1) clip to the stud on the front of dash. 13. Install the mega fuse cover (3). 14. Install the auxiliary battery positive cable connector (1) to the UBEC. Page 16824 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 15477 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 11762 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 18292 4. Insert a suitable tool (1) into the sunshade cam locking hole (2). 5. Turn the sunshade (1) counterclockwise until the shade cam (2) is align with the bracket (3) notch. Page 18224 Page 6390 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 3569 Note The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation. 1. Position the crankshaft balancer (138) onto the end of the crankshaft. 2. Install the J 41665 and the threaded rod from the J 41478 to crankshaft balancer and install the balancer. 1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer. 2. Use a wrench and hold the hex end of the threaded rod. 3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft. 4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer. 5. Use a wrench and hold the hex end of the threaded rod. 6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft. 7. Remove the J 41665 and the threaded rod. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Special Tools J 41478 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair) . 2. Remove the crankshaft front oil seal (140) from the front cover. Installation Procedure Important: * Do not lubricate the oil seal sealing surface. * Do not reuse the crankshaft front oil seal. Page 18273 Trailer Brake Control Relay (JL1) Trailer Brake Control Switch (JL1) Page 20814 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 1348 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 15328 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Page 12082 Fuse Block - Underhood X4 Page 3930 1. Position the intake manifold sight shield on top of the intake manifold, aligning the holes, if required. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the intake manifold sight shield retainer bolts, if required. Tighten the bolts to 5 Nm (44 lb in). 3. Install the intake manifold sight shield tabs into the slots in the retainer. 4. Align the intake manifold sight shield grommets with the studs. 5. Gently push down on the intake manifold sight shield over the grommets, seating the intake manifold sight shield. 6. Close the hood. Page 758 3. Position the engine wiring harness electrical connectors and engage the retainers securing the connectors (2) to the ECM (1). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 9569 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Note Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Page 12643 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 19994 1 - X415 2 - J412 3 - J419 4 - Right Hip Lamp Harness 5 - Left Hip Lamp Harness 6 - J418 7 - J413 8 - X416 Page 8285 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Engine - Valve Lifter Tick Noise At Start Up Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 4790 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 8510 Fluid Pan: Service and Repair Transmission Fluid Pan Replacement Page 10924 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 4166 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 18634 Disclaimer Page 5732 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 4552 3. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 4. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. 5. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 6. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit Page 3674 Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Actuator: Locations Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) 1 - Output Shaft 2 - Pinion Bearing Spacer 3 - Pinion Head Bearing Assembly 4 - Pinion Shim 5 Stem Pinion 6 - Pinion Flange Nut 7 - Pinion Flange Washer 8 - Pinion Flange Assembly 9 - Pinion Seal 10 - Pinion Tail Bearing Assembly 11 - Carrier Housing 12 - Output Shaft Seal Assembly 13 Output Shaft 14 - Drain Plug Assembly 15 - Drain Plug Washer 16 - Fill Plug Assembly 17 - Fill Plug O-ring Seal 18 - Carrier Locator Pin 19 - Vent Connector 20 - Differential Case 21 - Ring Gear 22 - Output Shaft Bearing Assembly 23 - 8-Point Lock Ring 24 - Sleeve and Insert Assembly 25 Differential Side Bearing Assembly 26 - Differential Cross Pin Lock Page 1909 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 13853 X300 Engine Harness to Chassis Harness (HP2) Page 15132 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 6861 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 6299 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30/TZ0/MYC or MW7/M99 with NQG/NQF) Vehicle Speed Sensor (VSS) (MW7 Except NQG/NQF) Page 8101 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 6329 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass and additional 90 degrees using J 45059 . 9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pump/Service and Repair) . Page 4341 Disclaimer Page 16889 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot at 1,000 RPM........................................................................................ .......................................................................................................250 kPa (36 psig) at 2,000 RPM... .............................................................................................................................................................. ..............................290 kPa (42 psig) at 4,000 RPM............................................................................ ...................................................................................................................310 kPa (45 psig) Page 12998 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4996 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 14952 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 6880 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (Gas with LY6) Page 5709 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 13067 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Accessory Power Outlet - Center Seat (AZ3) Page 13869 X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 4249 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 12198 Fuse Block - Underhood Bottom View Page 1905 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 11564 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in) . Page 9419 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement) . 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution) . 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 3064 Junction Block - Rear Lamps X2 Page 7114 Locations Windshield Washer Pump: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 14894 Page 6068 Page 17339 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement Except YE9 or SLT Front Side Door Trim Panel Replacement (Except YE9 or SLT) Service and Repair Center Link: Service and Repair Relay Rod Replacement Special Tools J 24319-B - Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 2. Remove the steering linkage shock absorber from the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair) . 3. Remove the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 4. Remove the idler arm nut (6). Discard the nut. 5. Separate the idler arm (1) from the relay rod (5) using the J 24319-B - Puller . 6. Remove the pitman arm nut (4). Discard the nut. 7. Separate the pitman arm (2) from the relay rod using the J 24319-B - Puller . 8. Remove the relay rod from the vehicle. 9. Inspect the threads and seals on all steering related components. Repair or replace the components as necessary. Installation Procedure Page 7259 Page 12727 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 20514 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 15267 Page 12153 Page 1327 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 14020 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 13181 Page 13003 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 12999 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12184 Page 14452 Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 3. Rotate the steering linkage inner tie rod (2) counterclockwise while holding the steering gear rack stationary until the steering linkage inner tie rod separates from the steering gear rack (1). Note Note the direction the steering linkage inner tie rod washer is installed. This will be important when installing the new washer. 4. Discard the steering linkage inner tie rod washer. Installation Procedure Note Install the new steering linkage inner tie rod washer in the same direction as noted previously. 1. Install the new steering linkage inner tie rod washer on the steering gear rack. Note All threads must be clean prior to LOCTITE(R) application. Check the LOCTITE(R), or equivalent, container for the expiration date. Use only enough LOCTITE(R) to evenly coat the threads. 2. Apply LOCTITE(R) 262 or equivalent to the steering linkage inner tie rod threads. 3. Attach the steering linkage inner tie rod to the steering gear rack and hand tighten it. Page 2713 Page 10668 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 20450 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11092 Note Do not pry the EBCM from the BPMV. The EBCM must be pulled back evenly. 26. Using the loosened bolts as a guide, carefully pull the EBCM (1) evenly from the BPMV to release the electrical connectors. 27. Remove the EBCM bolts (1). Page 19355 Page 8078 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13294 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 13478 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9702 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 9449 7. Remove the collapsible spacer. Note When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure Page 2038 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 9657 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 7391 27 - Differential Pinion Thrust Washer 28 - Differential Pinion Gear 29 - Differential Side Gear Washer 30 - Differential Side Gear 31 - Output Shaft Snap Ring 32 - Differential Pinion Gear 33 - Differential Pinion Gear Thrust Washer 34 - Differential Side Gear 35 - Differential Side Gear Washer 36 - Differential Cross Pin 37 - Ring Gear Bolt 38 - Output Shaft Bearing Assembly 39 8-Point Lock Ring 40 - Sleeve and Insert Assembly 41 - Differential Side Bearing Assembly 42 Carrier Gasket 43 - Carrier Cover 44 - Tube Locator Pin 45 - Inner Output Shaft Thrust Washer 46 - Inner Output Shaft Bearing Assembly 47 - Inner Output Shaft 48 - Carrier Bolt 49 - Shifter Spring 50 - Shifter Fork 51 - Shifter Fork Rod 52 - Tube Bolt 53 - Shift Actuator Assembly 54 - Output Shaft Seal Assembly 55 - Output Shaft Bearing Assembly 56 - Tube 57 - Tube Gasket 58 - Output Shaft Locator Thrust Washer 59 - Output Shaft Thrust Washer 60 - Output Shaft Snap Ring 61 Shifter Sleeve Page 12703 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 15316 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Page 20742 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 14900 Air Door Actuator / Motor: Service and Repair HVAC - Manual Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Page 6845 Page 1952 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 7193 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12763 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3/DL3 Except YE9) Page 10267 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7035 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 11859 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2392 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3771 Inspect closely for the temporary steel sealing device (1) being positioned tightly to the gasket (2) as shown. Only a small corner (1) of the temporary steel sealing device may be observable, depending on orientation. Perform a visual inspection in order to verify that the oil leak is coming from the engine oil cooler hose/pipe adapter area or the gasket where it connects to the engine. ‹› If the leak is coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, proceed to Step 4. ‹› If the leak is not coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, refer to Oil Leak Diagnosis in SI. 4. To gain clearance, loosen or remove the engine oil cooler hose/pipe retaining bracket bolt (1). 5. Remove the engine oil cooler hose/pipe adapter bolts (2). 6. Remove and DISCARD both the temporary steel sealing device if present and the gasket. 7. Clean the mating surfaces of the engine oil cooler hose/pipe adapter and the engine. 8. Clean both bolt holes with brake cleaner and dry using regulated compressed air. 9. Clean both bolt threads and apply Pipe Sealant P/N 12346004 (Canada P/N 10953480) or equivalent (Loctite(R) 565) to the bolt threads. Verify that the sealant is applied 360 degrees around the bolt and extends from the tip of the bolt and covers at least 15 mm (0.59 in) of threads. 10. Install the engine oil cooler hose/pipe adapter with a NEW gasket. Page 19470 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 1328 Braking Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Piston Position Sensor (HP2) Page 20412 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) 09-01-39-004A - END OF INFORMATION NEED Control Module HVAC: Technical Service Bulletins 09-01-39-004A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-01-39-004A Date: October 29, 2009 Subject: EI09086 - Automatic HVAC Inoperative, Automatic HVAC Control Replacement or Reprogramming (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK All Equipped with Automatic HVAC (RPO CJ2) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-01-39-004 (Section 01 - HVAC). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 11741 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 6587 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 7051 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 1817 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Page 19382 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 5114 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 12162 Page 17191 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 8289 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11306 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 13460 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 5454 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13446 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 11318 Page 19403 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 12055 Page 17558 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) Page 13362 Junction Block - Right I/P X2 Fuse Block - Auxiliary Radiator Cooling Fan Motor Relay: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 3208 Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair) . Page 13103 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 2456 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 4425 Page 6628 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop ...................................................................................................................................................... No more than 20 kPa (3 psi) Page 6374 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Left Side Frame and Underbody Components (HP2) Front Seat Adjuster Replacement (Power) Power Seat Motor: Service and Repair Front Seat Adjuster Replacement (Power) Front Seat Adjuster Replacement (Power) Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 4. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 5. Connect a test lamp between the control circuit and the ignition circuit. 6. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. Page 5893 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 6. Remove the HO2S (1). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). Page 12077 Fuse Block - Underhood X2 Page 20198 Page 15769 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4604 Generator Control Module Temperature Sensor (HP2) Page 18968 Door Lock/Window Switch - Passenger X4 (AN3) Page 3500 Note Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 17863 6. Rotate the key until the instrument panel compartment lock cylinder rotates to about the 5 o'clock position. This will line up the notch at the rear of the instrument panel compartment lock cylinder with the tab in the instrument panel compartment latch housing. 7. Remove the instrument panel compartment lock cylinder from the instrument panel compartment latch by pulling on the key. Installation Procedure 1. Position the instrument panel compartment latch fork bolt in the up position. 2. Grasp the instrument panel compartment lock cylinder. Depress the rear-most, light-colored tumbler that is flush with the instrument panel compartment lock cylinder surface. 3. Insert the key. All the tumblers will now stay depressed. 4. Insert the instrument panel compartment lock cylinder, with the key inserted, into the instrument panel compartment latch housing. Ensure that the front projection pin is at the appropriate 8 o'clock position. The instrument panel compartment lock cylinder will drop into place. 5. Rotate the key counterclockwise until the key stops. 6. Remove the key, the tumblers will now release. The instrument panel compartment lock cylinder is now locked into the instrument panel compartment latch housing. 7. Install the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: )Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: ) . Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Page 9098 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 13840 X212 Instrument Panel Harness to Instrument Panel Extension Harness (Early Production Except Y91/MEX/HP2/8S8) Page 7385 Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 4209 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 13575 Junction Block - Rear Lamps X3 Page 7844 Body - Incorrect Sun Visor Label Child Seat: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 12203 Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Page 3857 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Service and Repair Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement Removal Procedure Note An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 3. Remove the engine wiring harness bracket nut (1). Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Page 12121 Page 18520 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12269 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 2719 Junction Block - Left I/P X9 (except MEX) Page 12099 Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Instrument Panel Fuse Block INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. Page 4502 Page 4786 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 5874 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 7681 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 10637 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Page 20978 Wiper Motor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 7109 Page 6238 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 12155 Fuse Block - Underhood Bottom View Page 7823 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 14449 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools J 8001 Dial Indicator Set Note This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 3. Install dial indicatorJ 8001 or equivalent between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the dial indicator position. 4. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to remove any lash. 5. Zero the dial indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the dial indicator. 8. Movement should not exceed 1 mm (0.04 in). If the movement exceeds 1 mm (0.04 in) then replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 9. Repeat this procedure for the other side of the vehicle. Page 7366 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 13806 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L and NQF/NQH) Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Page 12573 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 5642 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Page 14425 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34/KA9) Steering Wheel Control Switch - Right (UK3) Page 7151 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 7898 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 13518 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 6739 24. Remove the fuel rail bolts. Caution: * Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. * Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Notes * Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. * Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 25. Remove the fuel rail assembly. 26. Remove the fuel injector retainers (1). Page 9971 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 2171 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with the two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 6. Using a hydraulic press and an appropriate tool, remove the pinion. Page 12149 Page 447 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 10456 26 - Front Differential Case 27 - Differential Pinion Gear Shaft Lock Bolt 28 - Differential Side Bearing 29 - Differential Side Bearing Cup 30 - Front Differential Ring Gear 31 - Front Differential Half Carrier Location Pin 32 - Front Differential Bearing Adjuster Nut Lock 33 - Differential Pinion Gear 34 - Differential Pinion Gear Thrust Washer 35 - Differential Side Gear Thrust Washer 36 Differential Side Gear 37 - Differential Pinion Gear 38 - Differential Pinion Gear Thrust Washer 39 Front Differential Side Gear Spacer 40 - Front Differential Side Gear 41 - Front Differential Side Gear Thrust Washer 42 - Front Differential Drive Pinion Gear 43 - Differential Drive Pinion Gear Bearing Shim 44 - Front Differential Drive Pinion Gear Inner Bearing 45 - Front Differential Drive Pinion Gear Inner Bearing Cup 46 - Front Differential Drive Pinion Gear Bearing Spacer 47 - Front Differential Carrier Bushing 48 - Front Differential Carrier 49 - Front Differential Bearing Adjuster Nut Lock 50 - Bolt 51 - Front Differential Drive Pinion Gear Yoke Nut 52 - Front Differential Drive Pinion Gear Thrust Washer 53 - Front Differential Drive Pinion Gear Yoke 54 - Front Differential Drive Pinion Gear Bearing Dirt Deflector 55 - Front Differential Drive Pinion Gear Seal 56 - Front Differential Drive Pinion Gear Outer Bearing Cup 57 - Front Differential Drive Pinion Gear Outer Bearing 58 - Front Differential Carrier Bushing 59 - Differential Bearing 60 - Front Differential Bearing Adjuster O-Ring Seal 61 - Front Differential Bearing Adjuster 62 - Front Drive Axle Inner Shaft Seal 63 - Front Drive Axle Inner Shaft Retaining Ring 64 - Front Drive Axle Inner Shaft 65 Front Differential Carrier Vent 66 - Fuel and Oil Resistant Hose 67 - Clamp 68 - Front Differential Carrier Vent Hose Connector 69 - Front Differential Carrier Oil Drain Plug 70 - Front Differential Carrier Oil Drain Plug Washer 71 - Front Differential Carrier Oil Fill Plug 72 - Front Differential Carrier Oil Fill Plug Washer Page 6472 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 15474 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 10302 Page 6698 1 - Turbocharger Vane Position Control Solenoid Valve 2 - Glow Plug Control Module (GPCM) 3 Fuel Temperature Sensor 4 - Intake Air Temperature (IAT) Sensor 2 Connector 5 - X128 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Generator - Auxiliary (K76/YF2) 8 - A/C Compressor Clutch (C67/CJ2) 9 - Engine Coolant Temperature (ECT) Sensor 10 - Camshaft Position (CMP) Sensor 11 - X127 12 - Generator 13 - Manifold Absolute Pressure (MAP) Sensor 14 - Intake Air Heater (IAH) 15 - Intake Air Temperature (IAT) Sensor 2 16 - Fuel Heater 17 - A/C Low Pressure Switch (C67/CJ2) Page 13301 Fuse Block - I/P X2 (except MEX) Page 2331 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement (V8) Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory) . 2. Remove the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. Page 12776 Page 6477 Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 18469 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 806 Page 7313 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 15546 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series with Crew Cab Except ASF) Page 4520 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 1377 Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Page 8770 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14739 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Page 6181 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 14872 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 12117 Junction Block - Left I/P X13 (AN3) Page 18483 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Passenger Seat Components - 1 of 2 Page 12231 Junction Block - Left I/P X3 (except MEX) Page 8100 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 12264 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Page 20933 Windshield Washer Pump: Service and Repair Washer Pump Replacement (Silverado) Page 19706 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 14738 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the bolt and tighten to 40 Nm (30 lb ft) . 4. Install the collar to the hoist 5. Install the shaft to the hoist. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Interior - Carpet Curling At Front Edge Carpet: All Technical Service Bulletins Interior - Carpet Curling At Front Edge TECHNICAL Bulletin No.: 09-08-110-002 Date: January 27, 2009 Subject: Carpet Curling at Front Edge (Install Velcro Fastener) Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Condition Some customers may comment that the carpet is curling at the top front edge (1). Cause The front edge of the carpet assembly may be folded before installation into the vehicle at the time of manufacture. After installation, the edge of the carpet may begin to curl due to the fold condition. Correction Important: Do not replace the carpet assembly. Use the following steps to correct the condition. 1. Clean the carpet backing and the dash pad surface with general purpose adhesive cleaner in the area where the Velcro is to be applied. 2. Install two 100 mm (3.90 in) long strips of Velcro loop material, GM P/N 12520273, to the dash pad as shown (1). 3. Install two 100 mm (3.90 in) long strips of Velcro hook material, GM P/N 12520271 to the corresponding area of the carpet assembly. 4. Apply firm pressure to the repair area to ensure that the adhesive backing on the Velcro bonds to the surface. Warranty Information Page 13072 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 12336 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 14153 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 1473 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 13735 X150 Inline Harness Connector End Views X150 Engine Harness to I/P Harness (HP2) Page 5585 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 3328 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 4549 10. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 11. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seal. * If pressure remains at the specified value, proceed to the next step. 12. Remove all GE-48494 - adapter kit components. 13. Remove the PIM cover retaining bolts (1). 14. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 15. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Page 1419 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9033 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 14641 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 15916 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15333 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 1650 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 2005 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 12144 Fuse Block - I/P X4 Page 6810 Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 15392 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 4142 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 5217 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Page 6783 See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 9977 Page 4985 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 6588 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 14338 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 12047 Fuse: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 7279 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 8876 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 5583 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 1439 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Page 12437 Junction Block - Left I/P X3 (except MEX) Page 19950 Page 18462 Page 11018 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Page 3783 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt. Tighten the bolt to 25 Nm (18 lb ft). 2. If equipped with a RPO L76 (6.0L) engine, perform the following. 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Page 5712 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 4615 Drive Motor Control Module: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 2505 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft) . 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. Page 20252 Page 7029 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 7276 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 20465 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 12366 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 12020 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 9446 Note Ensure that the outer bearing assembly rotates freely in the hub 5. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the wheel hub over and seat the outer bearing assembly against the retaining ring. 6. Turn the wheel hub over and install the inner bearing cup. 7. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 8. Install the inner bearing. Page 6498 1. Connect the EVAP line quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 2. Connect the EVAP line quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 7383 Page 2599 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 1084 Page 17714 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Page 15788 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16861 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 2182 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 18043 Page 17340 SLT, A95 Front Side Door Trim Panel Replacement (SLT, A95) Page 2789 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 6490 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 20515 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 14412 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 18298 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement Sunroof Sunshade Stop Replacement Page 8157 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 4648 3. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 4. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. 5. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 6. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit Page 8737 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 18810 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 18478 Page 16535 Disclaimer Page 17161 Page 9008 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 8677 - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 12407 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 4892 Page 4331 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Page 503 Control Module HVAC: Diagrams HVAC Control Module Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67/C42/MEX) Page 12320 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 1073 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 4191 Page 6951 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 8203 Page 13312 Page 11918 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 653 Auxiliary Body Control Module (XBCM) X1 (EXP) Page 19443 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 12447 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 345 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 12641 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Page 5716 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4521 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 11025 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 2. Drain all the brake fluid from the caliper. Note The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 9396 8. Using the J 22912-B - remover and a hydraulic press, remove the inner pinion bearing from the differential pinion gear. Note * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift, remove the outer pinion bearing cup. Note * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Using a hammer and a brass drift, remove the inner pinion bearing cup. A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 18545 Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Page 722 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 16721 Page 4908 Page 20740 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 17747 For vehicles repaired under warranty, use the table above. Disclaimer Page 591 Page 542 Page 12451 Page 10737 23. Remove the BPMV assembly from the bracket (1). 24. Remove the sleeves and insulators from the BPMV, if necessary. 25. If replacing the BPMV, loosen but do not remove the EBCM bolts (1). Page 17737 Page 15645 Malfunction Lamp / Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Page 4969 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 9248 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Page 11710 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 3054 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Page 7211 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 2750 Fuse Block - I/P X4 Page 10279 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 1523 Drive Motor Generator Battery Control Module X4 (HP2) Page 10321 Page 3012 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 12215 Fuse Block - Auxiliary X1 (HP2) Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 5223 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 7689 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 16809 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 6948 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 15390 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 12676 Multiple Junction Connector: Diagrams X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Page 8136 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 6654 ‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. AFIT Test Procedure 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays OPEN ‹› If the hood position does not display OPEN, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Turn OFF all accessories. 4. Turn OFF the ignition. 5. Install the AFIT. Refer to the AFIT User Guide. 6. Turn ON the AFIT and select the vehicle. 7. Turn ON the ignition and perform the Injector Test. ‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer toFuel Injector Diagnosis (w/CH 47976) Fuel Injector Diagnosis (w/J 39021 or Tech 2) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Diagnosis (w/J39021 or w/Tech 2)) . 8. View the test results. ‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other engine, refer toFuel Injector Cleaning (See: Service and Repair/Procedures) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Page 4702 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 5694 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Engine Controls - Cruise Control Turns Off When Operated Cruise Control: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11711 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 20189 Page 18550 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Page 10717 Page 11727 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 8644 Page 10380 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 11774 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 660 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Page 1022 Page 20608 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Page 17244 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 10746 19. Install the ABS module splash shield (1). 20. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . Page 10081 Input Shaft Seal Replacement Input Shaft Seal Replacement Page 7354 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12653 Page 19415 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 19680 * Easy Exit Recall * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy serial data message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via a serial data message. The instrument panel cluster receives a serial data message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting . Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a serial data message with the fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a serial data message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a serial data message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Page 8833 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 3069 Page 17109 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 19545 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 13536 Fuse Block - Auxiliary (HP2), Bottom View Page 14858 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Page 16901 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 7563 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 12118 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 4936 Page 5872 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 9204 1. A new Internal Mode Switch (IMS) has been added (2). The PSM has been deleted. ^ Do not reuse the roll pin that retains the IMS (2) to the manual shaft (3). ^ Do not remove the "C" clip from the IMS (2). This will damage the part. 2. The manual shaft (3) has been redesigned to accommodate the IMS (2). 3. The actuator rod (1) is a new design and will back service. It has a flat on the rod to accommodate the IMS (2). The wiring harness has been changed and now has the temperature sensor (2) in the harness with a gray connector. Both the 20-way connector (1) and the 6-pin connector for the IMS are now blue in color (3). The new DTCs shown above have been added for the IMS. Disclaimer Page 18554 Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Page 4670 * Accessory DC power control module (APM) * Battery energy control module (BECM) * Motor control module (MCM) 1 * Motor control module (MCM) 2 * Auxiliary transmission fluid pump (ATFP) control module These modules diagnose their own operation and determine when a fault condition is present. Diagnostic status is communicated to the HPCM through the following circuits: * APM utilizes the GM Hi-speed, Hybrid LAN communication circuit * BECM utilizes the GM Hi-speed, Hybrid LAN communication circuit * Each MCM and the HPCM exchange information and commands on the SPI bus internal communication circuit as well as the hi-speed hybrid GMLAN communication circuit. * ATFP control module utilizes a dedicated diagnostic status circuit In the event a hosted module communicates a fault condition, the HPCM will determine if hybrid operation is effected and notify the vehicle operator by requesting the MIL illuminate and/or by displaying a hybrid service required message. In addition, the HPCM will store the associated DTC information for retrieval by a scan tool. Some hosted modules may require an ignition cycle to clear certain DTCs from the HPCM. Circuit Inputs In addition to GMLAN parameters, the HPCM directly monitors the following signal circuits: * Transmission shift selector internal mode switch (IMS) Direction and Park/Neutral switch signals * Engine crankshaft position (CKP) sensor signal * ATFP diagnostic circuit * High voltage interlock circuit (HVIC) Circuit Outputs In addition to GMLAN and SPI bus commands, the HPCM directly controls the following output circuits: * ATFP control circuit * BECM high voltage contactor relay pulse width modulated (PWM) control circuit Motor Control Module (MCM) 1 and 2 Location Each electric motor generator located within the transmission assembly is controlled by its own motor control module (MCM) flash-programmable, micro-processor. Each MCM is contained within the PIM. Also contained within the PIM is the hybrid powertrain control module (HPCM) micro-processor. Operating Functions Each MCM operates the applicable electric motor generator based upon HPCM commands. Each MCM controls the speed, direction and output torque of its respective traction motor through the sequencing actuation of high current switching transistors called insulated gate bipolar transistors (IGBTs). Communication and Hosted Diagnostics In addition to the internal SPI bus communication circuit between the HPCM and each MCM, the MCMs also communicate on the Hi-speed and Hybrid GMLAN communication circuits. The MCM does not store its own diagnostic trouble code (DTC) information. The HPCM will store MCM associated DTC information for retrieval by a scan tool. The scan tool can communicate directly with each MCM in order to retrieve data parameters only. Circuit Inputs In addition to GMLAN parameters, each MCM monitors its respective motor generator for voltage, current, speed, direction and temperature. Additionally, the MCM monitors the IGBT components for temperature and proper operation. Some of the MCM operation data is shared with the HPCM. Circuit Outputs Each MCM controls its respective IGBT driver board that in-turn controls each motor generator. The motor generators operate using three-phase alternating current (AC) electricity. Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician that the potential for high voltage is present. Page 9395 Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (10.5 Inch Axle) Drive Pinion Bearings Replacement (10.5 Inch Axle) Special Tools * J 8092 - Universal Driver Handle - 3/4 in - 10 * J 8608 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22761 - Side Bearing Installer * J 22912-B - Bearing Remove * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 3. Remove the pinion gear bearing retainer. Refer to Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axle) (See: Drive Pinion Bearings Replacement (8.6, 9.5, 11.5 Inch Axle))Drive Pinion Bearings Replacement (10.5 Inch Axle) . 4. Remove the pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 5. Remove the outer pinion bearing. 6. Using an hydraulic press and the appropriate supports, remove the differential pinion gear. 7. Remove the collapsible spacer. Page 8838 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13805 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L Except NQF/NQH/HP2) Page 1498 Drive Motor Generator Battery Control Module X5 (HP2) Page 14356 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 3028 Page 12715 Page 10731 4. Remove the ABS module splash shield bolts (1). 5. Remove the ABS module splash shield (1). 6. Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake pipe fittings. Page 11526 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Battery/Battery Cable/Negative/Service and Repair) . Page 4469 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 11917 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 2497 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. Page 12614 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 20549 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 10978 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement) . 2. Remove the brake shoe adjuster actuator lever spring (1). 3. Remove the adjuster actuator lever (1). Page 10894 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Page 5074 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 20874 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 HUMMER H2 1. Open the hood and disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. 4. Remove the two relays next to the fuse to gain access to the fuse. 5. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 6. Discard the 60 amp heated windshield washer fuse. 7. Install the two relays removed in Step 4. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Buick Enclave Page 4933 Page 1455 Page 19821 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 2172 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Passenger Compartment/Roof Component Views Overhead Console Components Page 10122 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 6045 Engine Control Module (ECM) X2 (4.8L/LY6 or 6.2L with Y91) Page 5807 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The communication among control modules is performed through the high speed GMLAN serial data circuits and the low speed GMLAN serial data circuit. The modules that need real time communication are attached to the High Speed GMLAN network. The body control module (BCM) is the gateway between the high and low speed networks. Refer to Body Control System Description and Operation (See: Body and Frame/Body Control Systems/Description and Operation) for more information about the gateway. Signal supervision is the process of determining whether an expected signal is being received or not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If such a signal is lost, the signal supervision part of the software will set a no communication DTC (U. code) against the missing device. This code is mapped on the Tech 2 screen as a code against the physical device. A lost communication DTC typically is set in modules other than the module with a communication failure. GMLAN High Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is after the electronic brake control module (EBCM), or if equipped, the suspension control module. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds 1 volt to the high speed GMLAN serial data bus (+) and subtracts 1 volt from the high speed GMLAN serial data bus (-) wire. If a communication signal is lost, the application will set a no communication code against the respective control module. This code is mapped on the Tech 2 screen as a code against the physical device. Note: a loss of serial data DTC does not represent a failure of the module that the code is set in. The high speed GMLAN serial data allows communication between the body control module (BCM), ECM, transmission control module (TCM), vehicle communication interface module (VCIM), 4WD control module, EBCM, and the suspension control module depending on RPO. GMLAN Low Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low, 0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN low speed serial data buss, a wake up signal is sent out over the buss. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in GMLAN High Speed Circuit Description above. The modules on the GMLAN low speed serial data buss are connected to the buss using several splice or "star" connectors separating groups of modules. The following lists state the splices and modules connected to the low speed serial data circuits: I/P Splice * Data link connector (DLC), connected only to the instrument panel (I/P) splice * Amplifier (Amp) * Rear seat audio (RSA) * Vehicle communication interface module (VCIM) * Digital radio receiver (DRR) * Inside rearview mirror module (ISRVM), connected through the mid I/P fuse block * Instrument panel cluster (IPC) * Body control module (BCM) * Theft deterrent module (TDM) * Heater ventilation and air conditioning (HVAC) * Radio * Driver door switch (DDS), connected through the left I/P fuse block * Passenger door switch (PDS), connected through the right I/P fuse block Body Splice * Articulating running board module (ARBM) * Ultrasonic park assist (UPA) * Memory seat module (MSM) * Liftgate module (LGM) * Passenger presence system (PPS) * Inflatable restraint vehicle rollover sensor (ROS) * Inflatable restraint sensing and diagnostic module (SDM) Data Link Connector (DLC) Page 18594 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 18689 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 7379 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11135 Master Cylinder Replacement (JH6, JH7) Master Cylinder Overhaul Page 4172 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Page 13137 Fuse: Locations Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 11886 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 3315 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 12229 Junction Block - Left I/P X2 (except MEX) Page 12221 Page 8766 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 11282 Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Parking Brake Lever Pedal Assembly Replacement Removal Procedure Note The following service procedure includes the removal of the front park brake cable. The front park brake cable is NOT serviced separately, but serviced with the park brake pedal assembly. 1. Remove the left side hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Disconnect the park brake warning lamp electrical connector. 3. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Disabling) . 4. Remove the bolt and disconnect the park brake pedal release handle from the instrument panel. 5. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 7. Disconnect the front park brake cable from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 8. Release the front park brake cable from the frame by depressing the locking tabs. 9. Lower the vehicle. Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 13065 Page 477 Page 5674 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 56 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 2834 Page 6409 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 13306 Page 6722 Service and Repair Automatic Volume Control: Service and Repair Radio Volume Compensator Interior Noise Microphone Replacement Page 8545 3. Remove the auxiliary fluid pump control module electrical connector (1) from the auxillary fuse block. 4. Remove the auxiliary fluid pump control module (2) from the engine control module bracket. Installation Procedure 1. Install the auxiliary fluid pump control module (2) to the engine control module bracket. 2. Install the auxiliary fluid pump control module electrical connector (1) to the auxillary fuse block. Page 14039 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 3590 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 15594 Inflatable Restraint Front End Sensor - Left (10 Series) Page 3959 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 6796 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew cab w/34 Gal Tank) Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Service and Repair Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Page 10653 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) Page 16619 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 8775 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2371 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 1867 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 17836 Front Floor Console Replacement (without RPO SLT) Front Floor Console Replacement (without RPO SLT) Component Locations Seat Position Sensor: Component Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 2777 Fuse Block - Auxiliary (HP2), Top View Page 8977 Module Circuit Function Icons Diagrams Barometric Pressure Sensor: Diagrams Component Connector End Views Barometric Pressure (BARO) Sensor (HP2) Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 8195 Switches and Relays Page 16719 Radio Rear Side Door Speaker Replacement (Extended Cab) Radio Rear Side Door Speaker Replacement (Extended Cab) Page 11367 5. Slide the trailer brake control module (1) toward the center of the vehicle and remove the trailer brake control module. Installation Procedure 1. If installing a new trailer brake control module, hand start the 3 trailer brake control module bolts. 2. Position the trailer brake control module to the frame bracket. 3. Slide the trailer brake control module (1) toward the left frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 2282 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 18745 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Hood Hinge Replacement Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Page 20640 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Passenger Door Components (except AN3/DL3) Page 3980 9. Using the J 41816-2 (1), the J 41558 (2), bolts (3) and the J 8433 (4) in order to remove the crankshaft sprocket. 10. Remove the crankshaft sprocket (207). Page 14878 Air Door Actuator / Motor: Service and Repair Mode Valve Actuator Replacement Mode Valve Actuator Replacement Page 11668 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 9160 Page 18974 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Page 12046 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Page 5308 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 13879 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3/DL3 Except YE9) Page 7846 Control Solenoid Valve Assembly X3 (MYC/MYD) 1-2 Shift Solenoid (SS) Valve (M30) Page 10227 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5303 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 5283 Fuel System Diagnosis (w/FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Important: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Ignition OFF, all accessories OFF, install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4 - 310.3 Page 12219 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 5198 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 8620 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 510 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Page 4661 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 12389 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 14091 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Diagrams Power Distribution Module: Diagrams Component Connector End Views Accessory DC Power Control Module X1 (HP2) Accessory DC Power Control Module X2 (HP2) Page 16303 Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components (X88) Page 17510 Page 10512 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 15734 Disclaimer Page 2721 Junction Block - Left I/P X11 (except MEX) Page 5664 Page 15204 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 2293 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 4. If the right side spark plug wire(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . Page 11053 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Page 11861 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 18859 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11418 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring recepticle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Page 18835 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 3928 1. Install the upper intake manifold cover. 2. Install the upper intake manifold cover nut until snug 3. Install the brake booster vacuum hose to the intake manifold nipple. 4. Position the brake booster vacuum hose clamp at the intake manifold. 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: ) . Service and Repair Universal Joint: Service and Repair Universal Joint Replacement Special Tools * J-9522-3 - U-Joint Bearing Separator * J-9522-5 - U-Joint Bearing Spacer Remover Removal Procedure Caution: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. Note The following service procedure can be used for either the external retaining ring or the nylon injected ring. Note If replacing the propeller shaft slip yoke, proceed to step 10. 1. Using a hammer (2), tap the yoke (1) lightly in order to relieve the pressure from the universal joint retaining ring. Page 18206 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Front Propeller Shaft Replacement Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Page 91 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 14790 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 3014 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 2004 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 14263 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 12518 Page 7965 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 4875 Page 11489 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 5850 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 3651 Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). Page 19370 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 16432 - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 7. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio Important None of these device lists below support video. Important Not all iPhone functions are fully supported. For further information on identifying iPod models, please visit http://support.apple.com/kb/HT1353. Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to mass storage class (MSC) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Page 11937 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 9157 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 2900 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 6504 Important: Route the PCV tube between the engine harness and generator battery jumper cable. 3. Install the PCV fresh air tube (1) to the air cleaner outlet duct, if required. 4. Install the PCV dirty air hose to the intake manifold fitting and left valve rocker arm cover, if required. 5. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 19438 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 9923 Transfer Case Actuator: Locations Powertrain Component Views Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 2043 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Page 13231 Junction Block - Left I/P X11 (except MEX) Page 15982 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Under the Front Seats Components Page 18541 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Page 10968 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Spoecial Tools J 8001 Dial Indicator Set, or equivalent Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured alcohol or an equivalent approved brake cleaner. 2. Inspect the braking surface of the brake drum for the following braking surface conditions: * Heavy rust and/or pitting-Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights 3. If the braking surface of the brake drum exhibits 1 or more of the braking surface conditions, the drum requires refinishing or replacement. 4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 5. Compare the groove, scoring, depth recorded to the following specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in). 6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. 7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator,J 8001 or equivalent, and position the indicator button so it contacts the braking surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer edge. 9. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum allowable radial runout 0.06 mm (0.0024 in). 11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Page 19677 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 17333 Door Latch - Passenger Page 8234 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8275 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 7747 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 808 Page 10077 Seals and Gaskets: Service and Repair MP 1625/1626-NQF - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Page 13891 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Page 12856 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 12957 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 17994 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Page 105 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 6010 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 13822 X129 Inline Harness Connector End Views X129 I/P Harness to Chassis Harness (HP2) Page 8277 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12129 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Underhood Fuse Block UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. Page 11601 9. Remove the positive battery cable nut (1) from the mega fuse stud. 10. Remove the positive battery cable nut (3) from the auxiliary BEC stud. 11. Disconnect the positive battery cable connector (2) from the underhood BEC. 12. Remove the positive battery cable assembly (1) from the vehicle. Installation Procedure Page 2663 Fuse Block - Auxiliary (HP2), Top View Page 12322 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 426 6. Remove all dirt and debris from the electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV). 7. Disconnect the EBCM electrical connector. 8. Loosen, but do not remove, the EBCM bolts (1). Note Do not pry the EBCM from the BPMV. The EBCM must be pulled away from the BPMV evenly. 9. Using the loosened EBCM bolts as a guide, carefully pull the EBCM (1) evenly away from the BPMV to release the electrical connectors. Page 8198 Page 13223 Page 14941 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 19695 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 1140 Page 16942 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 20078 Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 13031 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 8600 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 6276 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 13412 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1920 Crankshaft Position (CKP) Sensor (Diesel) Page 11399 Electronic Brake Control Module (EBCM) (JH6/JH7) Page 17421 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 8232 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 18450 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 10059 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Page 15989 Page 7119 Page 13868 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Page 4639 15. Install the HV dc battery cable (6) with seal (7) into the PIM distribution box. 16. Install the HV dc battery cable mounting fasteners (5). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 17. Install the high voltage (HV) dc battery cable terminal fasteners (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 18. Install the HV dc electric air conditioning compressor module (ACCM) cable (4) with seal (7) into the PIM distribution box. 19. Install the HV dc electric ACCM cable mounting fasteners (3). Tighten the mounting fasteners to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 20. Install the HV dc electric ACCM cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . 21. Install a new seal (3) on the PIM distribution box. Page 1977 Page 20283 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 9372 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities andFluid and Lubricant Recommendations . 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. Page 9750 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13440 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 4691 Drive Motor Control Module: Service and Repair Accessory DC Power Control Module Removal and Installation Accessory DC Power Control Module Removal and Installation Special Tools * J 24460-01 - Cooling System Pressure Tester * GE-48494 - Power Electronics Pressure Test Adapter Kit Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the APM ground strap bolt (1) and ground strap (2). Page 20879 16. Return to the appropriate the Fuse Removal service procedure in this bulletin to continue this repair. Question and Answer Section Question and Answer Section Q1. Why are we compensating customers for a recall? A1. This is a special case where we are not confident a repair would work. This is why we are removing this feature from the vehicle. Compensating the current customer of record for this loss is an appropriate gesture. Q2. What is the original cost of the Heated Washer Fluid System? A2. The system was priced in several ways; as standard equipment, as a stand-alone option and as part of an option package. We analyzed these scenarios and determined that $100 is an appropriate estimate of the value of the feature. Q3. How much will each customer receive? A3. Customers will receive a $100 check from their servicing dealer within 30 days of recall completion. Q4. Why can't GM issue the checks? A4. Due to their age, our original sales records will not reflect any subsequent vehicle transactions or owner changes. Additionally, we don't have an in-house system that can handle this number of checks. So we are depending on our dealers to help execute this safety recall. Q5: When will customers be notified about having this feature disabled? A5: Customers should begin receiving letters in the mail in mid-June. However, they can go to their local dealer any time (even in advance of receiving a letter) to have the system disabled. Q6. Are all of the VINs involved in this recall identified in the GWM-IVH (GMVIS2) application? A6. Yes, all involved VINs have been updated for this recall. Q7. How do I identify the current customer of record? A7. For the purposes of this recall, the current customer of record is to be identified as the person or company whose name appears on the vehicle's state registration document or other legally recognized proof of vehicle ownership (unless specifically excluded). Prior to issuing the $100.00 check, please ensure the proof of ownership documentation has not expired and is otherwise valid. Q8. What should I do if proof of vehicle ownership is not available? A8. If proof of vehicle ownership documentation is not currently available or is otherwise invalid, the $100 check should not be issued. Q9. What if the customer objects to this policy? A9. If valid proof of ownership documentation is not available, the decision not to issue the $100 check is correct. If the customer still disagrees, please refer him/her to the GM Customer Assistance Center. Q10. If a check is not issued, how should the recall claim be submitted? A10. If a final determination is made not to issue a check, the $100 net item amount should not be claimed. Only the labor cost for the repair should be submitted. Q11. Can you provide examples of the various customer scenarios I can expect? A11. Certainly, listed below are examples with the preferred resolution. ^ Retail Customer - Vehicle Purchased Issue check to the customer at vehicle pickup if valid proof of vehicle ownership documentation is available. All checks must include the complete 17 character Vehicle Identification Number. ^ Retail Customer - Vehicle Leased Issue check to the customer at vehicle pickup (not GMAC or other financial institution) if valid proof of vehicle ownership documentation is available. Page 4593 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 10401 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 11604 9. Install the auxiliary BEC cover (1). 10. Install the positive battery cable terminal (3) to the battery. 11. Rotate the lever lock (1) clockwise until an audible click is heard in order to connect the positive battery cable. 12. Position the positive battery cable insulating cover (2) over the positive terminal. 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair) . Page 2837 Junction Block - Left I/P X3 (except MEX) Page 4734 Generator Battery Vent Fan Relay (HP2) Page 781 Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas Except LU3/LY6) Page 8388 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 17126 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 10398 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13715 Page 7318 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 10270 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12029 Page 3784 Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 lb ft). 3. For 2500 series vehicles, raise the differential carrier into position. 4. Install the differential carrier left side upper bolt and nut until snug. 5. Install the differential carrier left side lower bolt and nut until snug. 6. Install the differential carrier right side nuts. Tighten the bolt to 100 Nm (74 lb ft). 7. For 1500 series vehicles, raise the differential carrier into position. 8. Install the differential carrier right side nuts. 9. Install the differential carrier left side bolts. Page 15937 Disclaimer Page 9703 Director, Customer and Relationship Services 09241 Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 8021 Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF/NQH) Page 9039 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13605 Fuse Block - I/P X4 Page 19431 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10906 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Page 11197 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 3045 Junction Block - Left I/P X5 (SPO Alarm) Page 2231 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Fuel Injector Diagnosis (w/J 39021 or Tech 2) Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (w/J 39021 or Tech 2) Fuel Injector Diagnosis (w/J 39021 or Tech 2) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the system fuel pressure that can be recorded and used to compare each injector. Diagnostic Aids * Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. * Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. * Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 39021 Fuel Injector Coil and Balance Tester * J 44602 Injector Test Adapter Component Testing Fuel Injector Coil Test 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . Page 12414 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 19906 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 20100 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14657 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 19476 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7849 Page 4717 Battery Current Sensor: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 15483 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Body - Incorrect Sun Visor Label Sun Visor: Customer Interest Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 13266 Body - Outside Door Handle Pulls Out of Base Rear Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 1198 Door Lock/Window Switch - Passenger X4 (AN3) Page 13262 Page 1448 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 40 Disclaimer Page 13365 Junction Block - Right I/P X4 Page 13012 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 894 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 6073 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Page 20165 Marker Lamp - Right Rear (Z88) Marker Lamp - Tailgate (RO5) Page 9558 Drive/Propeller Shaft: Diagrams Driveline Disassembled Views Front Propeller Shaft Front Propeller Shaft 1 - Propeller Shaft Universal Joint 2 - Propeller Shaft Tube 3 - Propeller Shaft Universal Joint 4 Propeller Shaft Slip Yoke 5 - Propeller Shaft Rear Slip Yoke Boot Clamp - Front 6 - Propeller Shaft Rear Slip Yoke Boot One-Piece Propeller Shaft Page 20461 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 4102 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 20329 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 18724 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Passenger Seat Components - 1 of 2 Page 15627 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series Except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series Except Crew Cab/MEX) Page 18393 Disclaimer Page 9062 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 7030 Camshaft Position (CMP) Sensor (Diesel) Page 6233 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 2624 Fuse Block - Auxiliary X2 (HP2) Page 5248 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 2948 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 20601 Window Switch - Left Rear (Crew Cab with A31/Extended Cab with ABV) Page 14404 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 6096 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Page 11895 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8686 Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Removal Procedure Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to service the HPA. Ensure that the recommended procedures are followed to relieve system pressure, including using the manual pressure release steps. Failure to properly follow procedures to depressurize the system may result in personal injury. Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the antilock brake system (ABS) module splash shield retainer (1). Page 13251 Junction Block - Rear Lamps X4 Page 12251 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 13329 Fuse Block - Auxiliary (HP2), Top View Page 12997 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 7500 Page 10341 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6359 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9980 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Page 368 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heatng and Cooling Module - Passenger (KB6) Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 12078 Page 5606 Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Special Tools * J 29532 Diaphragm Pressure Bleeder, orJ-29532-A Brake Pressure Bleeder, or equivalent * J 35589-A Brake Bleeder Adapter, or equivalent Warning At times during this brake bleed procedure brake fluid will be under higher pressures than during typical brake bleed procedures. Ensure the bleeder hose attached to the bleeder valve is securely maintained in position whenever the bleeder valve is opened. Failure to maintain the bleeder hose securely to the valve when opened, may allow the hose to blow off and brake fluid to spray out of the bleeder valve, possibly resulting in personal injury. Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings) . Note * Do not pressurize the brake pressure bleederJ-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. Portions of the automated bleed process require the master cylinder reservoir not be pressurized through the J-29532-A orJ 29532 . * Do not apply the brake pedal until instructed to do so by the scan tool. Applying the brake pedal before instructed by the scan tool may result in setting a DTC and may require the sensor and boost valve calibration and electronic brake control module (EBCM) learn procedures to be repeated manually. 1. Place the transmission in the PARK or NEUTRAL position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 2. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 5. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as necessary. 6. Lower the vehicle to allow for entry and exit while bleeding the brake corners and other components. 7. Connect a battery charger to the 12V battery. The battery charger must remain connected for the entire automated bleed procedure. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) . 8. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during the entire automated bleed procedure. 9. Turn the ignition switch to the ON position with the engine OFF. Note Do not pressurize the pressure bleederJ-29532-A orJ 29532 , and thereby the master cylinder reservoir, until instructed to do so by the scan tool. 10. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) Page 852 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab without 10 Series) Page 14435 Steering Shaft: Service and Repair Steering Shaft Coupling Replacement Steering Shaft Coupling Replacement Special Tools J 42640 Steering Column Anti-Rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Set the front wheels in the straight-ahead position. 2. Install anti-rotation pinJ 42640 in the steering column lower access hole. 3. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 4. Mark the relationships of the steering shaft coupling, the upper intermediate steering shaft, and the power steering gear. 1. Mark the relationship of the upper intermediate steering shaft to the steering shaft coupling. 2. Mark the relationship of the steering shaft coupling to the steering gear. Note DO NOT pull on the steering shaft coupling to separate it from the steering gear. 5. Remove the steering shaft coupling bolt at the steering gear. Page 7809 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 8102 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 756 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Disengage the engine wiring harness electrical connector retainers and remove the connectors (2) from the ECM (1). Page 3969 8. Using the J 41816-2 (1), the J 41558 (2), bolts (3) and the J 8433 (4) in order to remove the crankshaft sprocket. 9. Remove the crankshaft sprocket (207). Page 14803 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 12612 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Page 13608 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 19345 Technical Service Bulletin # 09-08-68-001 Date: 091114 Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 5885 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 4876 Engine Control Module (ECM) X1 (Diesel) Page 9581 3. Align the reference marks on the transmission or the transfer case (1), output shaft yoke (2), and the propeller shaft (6). Note When installing the propeller shaft bolts, hand tighten the bolts. DO NOT tighten them to specification until the center bearing support bolts have been installed and torqued to specifications. 4. Install the propeller shaft (2), the straps (3), the propeller shaft bolts (3) on the transmission or the transfer case (1). 5. Position the center support bearing (1) on the frame. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 1780 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 6475 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. 13. Install the fuel pipe bracket nut to the bellhousing stud and tighten the nut to 25 Nm (18 lb ft) . 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 15. Lower the vehicle. Page 8221 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 13541 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 19557 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12719 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Page 8205 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 15086 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 13241 Page 14656 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 15449 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 11972 Warranty Information (Saab U.S. Models) Disclaimer Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 12105 Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 2960 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 1762 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Page 9068 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 14084 Service and Repair Refrigerant: Service and Repair Refrigerant Recovery and Recharging (HP2) Special Tools * J 43600 ACR 2000 Air Conditioning Service Center * HP2 A/C Oil Injector A/C Oil Injector Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only polyolester refrigerant oil (POE) for internal circulation through the R1344a A/C system and only use 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (Non-HP2) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If POE oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. POE Oil can be injected into a charged system usingHP2 A/C Oil Injector .For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (Non-HP2). Page 14538 Disclaimer Page 12877 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 9429 Note Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement) . 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . 2. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: All Technical Service Bulletins Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 16638 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 2939 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 15195 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Page 6837 Fuel Pump and Sender Assembly - Front (MEX) Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 4616 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 10983 3. Install the primary brake (1) shoe return spring and position the primary brake shoe to the rear brake backing plate. Insert the hook end of the return spring to the brake shoe web from the outer face. 4. Install the lower brake shoe spring (1). Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Locations Brake Light Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 17865 Instrument Panel Compartment Door Replacement (With RPO SLT) Instrument Panel Compartment Door Replacement (With RPO SLT) Page 9148 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 3676 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Page 11893 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 12189 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 4575 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 10324 Page 9438 Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. 8. Place an alignment mark between the pinion and the pinion yoke. Note DO NOT reuse the pinion nut, replace with NEW. 9. Using the J 8614-01 - holder and remover , remove and discard the pinion the pinion nut. Note Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Page 15963 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Page 5675 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 11666 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 20730 Disclaimer Page 8082 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 15300 Page 2425 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 16266 Parking Assist Control Module: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Page 5012 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 8832 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5772 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 565 Page 1045 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 8467 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 5088 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 4644 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in ). Note Only use pre-mixed DEX-COOL(R) on the coolant pipe O-ring to aid in tube installation. 4. Lubricate the new seals (6, 9) with pre-mixed DEX-COOL(R). 5. Install new seals (6, 9) onto the drive motor generator power inverter coolant pipes (5, 8). 6. Install the coolant pipes (5, 8) to the PIM assembly with bolts (4, 7). Tighten the fasteners to 5 Nm (44 lb in) . 7. Rotate the drive motor generator control module assembly onto the APM. 8. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 9. Plug the remaining coolant pipe with the GE-48494 - adapter kit plug and clamp (1). Page 7820 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Specifications Water Pump: Specifications Water Pump Bolts - First Pass............................................................................................................. ............................................................15 Nm (11 lb ft) Water Pump Bolts - Final Pass....................... .................................................................................................................................................30 Nm (22 lb ft) Page 8237 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 13146 Page 20487 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10798 Page 2186 Sliding Rear Window Motor (A48) Sliding Rear Window Open Relay (A48) Page 12209 Page 17886 Page 8070 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 9585 Drive/Propeller Shaft: Tools and Equipment Special Tools Page 12660 Page 3113 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 13489 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 9516 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half ofJ 36652-1 orJ 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts intoJ 36652-1 orJ 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair/Front Wheel Drive Shaft Seal Protector Replacement) . 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 20573 Sliding Rear Window Open Relay (A48) Sliding Rear Window Switch (A48) Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 19965 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 3103 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 5173 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30/TZ0/MYC or MW7/M99 with NQG/NQF) Vehicle Speed Sensor (VSS) (MW7 Except NQG/NQF) Page 9506 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models orJ-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models orJ-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note Alternate between the bolts until both sides of the top half of the tool touch the bottom half . 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Page 7919 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 13497 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12726 X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X224 Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Page 7774 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 19596 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 20467 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 788 Page 10727 8. Install the ABS module splash shield retainer (1). Page 6729 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 9973 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 3643 8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the ignition coil bracket studs. 9. Position the ignition coil bracket (719) onto the rocker cover. 10. Install the ignition coil bracket studs (720). Tighten the studs to 12 Nm (106 lb in). 11. Install the spark plug wires (724) to the ignition coils. 12. Install the heater hose bracket (2) and nut (1). Tighten the nut to 9 Nm (80 lb in). Page 754 Page 1085 Page 17941 Page 20656 Sliding Rear Window Motor (A48) Sliding Rear Window Open Relay (A48) Page 10393 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9047 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 17381 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 8782 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 17104 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 3280 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 8096 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 20014 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Page 16503 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 1803 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 2524 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Page 6957 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Blower Motor Control Module Control Module HVAC: Diagrams Blower Motor Control Module Component Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 3513 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Replacement Camshaft Position Actuator Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . 2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234). Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 2106 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 19291 Disclaimer Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Page 3335 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 526 Page 15273 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 1786 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 13572 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Exhaust Manifold Replacement - Left SIde Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left SIde Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, 6.0L, and 6.2L) Special Tools J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Install the J 42640 into the steering column lower access hole. 2. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 3. Fully raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Remove the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar). 5. Lower the vehicle part way in order to work through the wheel opening. Page 19430 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 20907 use of any similar HWFS products that may be sold by aftermarket suppliers. Even though you have declined to have this safety recall performed on your vehicle, please be advised that if you change your mind, your GM dealer will always be available to remove the HWFS from your vehicle and provide reimbursement according to the terms described in the recall notification letter. As part of this declination process, your dealer will ask you to document your refusal to have Safety Recall 10153 performed on your vehicle by signing a Repair Order stating "customer declined recall repair". You will be given a copy of this document for your records. Of course, your signature is voluntary but doing so will help prevent the mailing of recall reminder notices to you as the current owner of record. If you sell this vehicle, you should advise the buyer that this safety recall was not performed on the vehicle and that the recall repair is still available. This notice should also be placed in the glove box so that a future owner of this vehicle will be aware of this safety recall. Page 12109 Junction Block - Left I/P X4 (except MEX) Page 4131 Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 20496 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 2403 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter (437) if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430). Tighten the drain plug to 25 Nm (18 lb ft). Page 1830 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 7. Remove the HO2S (4). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 6580 Page 19034 Seat Adjuster Switch - Passenger (AN3) Page 13825 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Page 18626 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 3406 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 10742 7. Through the frame crossmember, install the BPMV bracket bolts (1) and tighten to 22 Nm (16 lb ft) . 8. Tighten the lower BPMV bracket bolt (1) to 22 Nm (16 lb ft) . Page 12386 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 2895 Switches and Relays Page 10821 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 5041 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 597 Page 18535 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 20922 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Page 5697 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 8172 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2672 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 13407 Devices and Sensors Page 12891 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 5783 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 10242 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 14556 Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Link Style) Torsion Bar and Support Assembly Replacement (Link Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist and lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Install the J 36202 to the adjustment arm and the support assembly. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note Create a reference point for the adjustment bolt to the support. Count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjuster nut (4) from the support assembly (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. 7. Remove the adjustment arm (2) from the support assembly (1). Page 12104 Page 1596 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 8425 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 11737 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 8167 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 11868 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 3388 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. Page 734 Exhaust System - Rattle/Thud Noise On Left Turns/Bumps Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Rattle/Thud Noise On Left Turns/Bumps TECHNICAL Bulletin No.: 09-06-05-004 Date: May 20, 2009 Subject: Rattle or Thud Type Noise During Left Turns or While Driving Over Bumps (Perform Repair as Outlined) Models: 2007-2009 Chevrolet Silverado 1/2 Ton 1500 Series (Including Hybrid) 2007-2009 GMC Sierra 1/2 Ton 1500 Series (Including Hybrid) Condition Some customers may comment on a rattle or thud type noise during left turns or while driving over bumps. Cause This condition may be caused by contact between the front exhaust hanger and the frame hanger. Correction Perform the repair below to eliminate the contact between the front exhaust hanger and the frame hanger. 1. Raise and support the vehicle. 2. Measure the clearance (1) between the front exhaust hanger and the frame hanger. There should be at least 8 mm (0.315 in) clearance. Witness marks may also be visible. - If the clearance is less than specified, proceed to step 3. - If the clearance is within specification, diagnose and repair using the information found in SI. 3. Grind or file the front exhaust hanger head until the remaining material measures 4 mm (0.157 in). 4. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Page 8837 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 2858 Junction Block - Rear Lamps X2 Page 4686 4. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 5. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 6. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. Page 6814 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Page 6058 Page 88 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 6789 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 646 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Body Control Module (BCM) X2 Page 729 Page 12031 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 13060 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 6840 Page 19572 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Front Brake Rotor Replacement (JD9, JF3, JF7) Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JD9, JF3, JF7) Front Brake Rotor Replacement (JD9, JF3, JF7) Specifications Flex Plate: Specifications Automatic Transmission Flex Plate Bolts - First Pass.....................................................................................................................................20 Nm (15 lb ft) Automatic Transmission Flex Plate Bolts - Second Pass................................................................................................................................50 Nm (37 lb ft) Automatic Transmission Flex Plate Bolts - Final Pass..................................................................................................................................100 Nm (74 lb ft) Page 12978 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 3111 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 19654 Compass: Diagrams Component Connector End Views Electronic Compass Module (YE9) Page 8933 10. Remove the cable grommet from the floor panel. 11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 12. Remove the clips on the cable from the floor panel reinforcement. 13. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 14. Remove the range selector lever cable heat shield bolts (1). 15. Remove the range selector lever cable heat shield (2). 16. Ensure the transmission manual shaft is positioned in mechanical park. Page 11578 11. Install the negative battery cable clip (1) to the auxiliary BEC. 12. Connect the engine wiring harness electrical connector (1) to the battery current sensor (2). 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair) . Page 9462 12. Remove the inner hub bearing. 13. Using a brass drift and a hammer, remove the inner hub bearing cup. 14. Remove the retaining ring from the wheel hub. 15. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Page 2753 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 8504 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Page 5426 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 2849 Junction Block - Right I/P (Wire Entry) Page 11723 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 15399 Page 16345 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 18530 Seat Adjuster Switch - Passenger (AN3) Page 18284 Luggage Rack: Service and Repair Luggage Carrier Nut Replacement Luggage Carrier Nut Replacement Removal Procedure 1. Remove the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement) . Warning: Refer to Safety Glasses Warning (See: Service Precautions/Technician Safety Information/Safety Glasses Warning) . 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement) . Page 13762 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Page 16727 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Page 10295 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2993 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 2766 Page 5571 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 4410 Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 3250 Disclaimer Page 2650 Fuse Block - Underhood X6 Page 11820 Page 14310 Air Conditioning O-Ring Seal Replacement A/C Coupler O-ring: Service and Repair Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure * For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). * For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Page 10282 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12234 Junction Block - Left I/P X7 (JF4) Page 9099 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 8280 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Global Positioning System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 19909 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 18666 Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Page 6038 Page 10819 Page 12359 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 13520 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 1298 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 14303 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15516 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 1862 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 2689 Page 20866 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within Page 18826 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 7412 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case High/Low Shift Fork Pad 11 - Transfer Case High/Low Shift Fork 12 - Transfer Case High/Low Shift Fork Spring Assembly 13 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 14 - Transfer Case Two/Four Wheel Drive Actuator Cam Spacer 15 - Transfer Case Two/Four Wheel Drive Actuator Cam 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case High/Low Shift Fork Pin 18 - Transfer Case Actuator Shaft Gear 19 - Transfer Case Rear Output Shaft Assembly 20 - Transfer Case Front Output Shaft Drive Chain Assembly 21 - Transfer Case Front Output Shaft Drive Sprocket 22 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 10973 4. Remove the brake drum (1). 5. If the brake shoes prevent the brake drum from being removed, retract the brake shoe adjuster. Refer to Drum Brake Adjustment (See: Adjustments) . Installation Procedure 1. Using the J-42450-A - Wheel Hub Resurfacing Kit , remove any corrosion from the rear axle flange contact surface. 2. Install the brake drum (1). 3. Adjust the drum brakes. Refer to Drum Brake Adjustment (See: Adjustments) . 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 20903 16. Return to the appropriate the Fuse Removal service procedure in this bulletin to continue this repair. Question and Answer Section Question and Answer Section Q1. Why are we compensating customers for a recall? A1. This is a special case where we are not confident a repair would work. This is why we are removing this feature from the vehicle. Compensating the current customer of record for this loss is an appropriate gesture. Q2. What is the original cost of the Heated Washer Fluid System? A2. The system was priced in several ways; as standard equipment, as a stand-alone option and as part of an option package. We analyzed these scenarios and determined that $100 is an appropriate estimate of the value of the feature. Q3. How much will each customer receive? A3. Customers will receive a $100 check from their servicing dealer within 30 days of recall completion. Q4. Why can't GM issue the checks? A4. Due to their age, our original sales records will not reflect any subsequent vehicle transactions or owner changes. Additionally, we don't have an in-house system that can handle this number of checks. So we are depending on our dealers to help execute this safety recall. Q5: When will customers be notified about having this feature disabled? A5: Customers should begin receiving letters in the mail in mid-June. However, they can go to their local dealer any time (even in advance of receiving a letter) to have the system disabled. Q6. Are all of the VINs involved in this recall identified in the GWM-IVH (GMVIS2) application? A6. Yes, all involved VINs have been updated for this recall. Q7. How do I identify the current customer of record? A7. For the purposes of this recall, the current customer of record is to be identified as the person or company whose name appears on the vehicle's state registration document or other legally recognized proof of vehicle ownership (unless specifically excluded). Prior to issuing the $100.00 check, please ensure the proof of ownership documentation has not expired and is otherwise valid. Q8. What should I do if proof of vehicle ownership is not available? A8. If proof of vehicle ownership documentation is not currently available or is otherwise invalid, the $100 check should not be issued. Q9. What if the customer objects to this policy? A9. If valid proof of ownership documentation is not available, the decision not to issue the $100 check is correct. If the customer still disagrees, please refer him/her to the GM Customer Assistance Center. Q10. If a check is not issued, how should the recall claim be submitted? A10. If a final determination is made not to issue a check, the $100 net item amount should not be claimed. Only the labor cost for the repair should be submitted. Q11. Can you provide examples of the various customer scenarios I can expect? A11. Certainly, listed below are examples with the preferred resolution. ^ Retail Customer - Vehicle Purchased Issue check to the customer at vehicle pickup if valid proof of vehicle ownership documentation is available. All checks must include the complete 17 character Vehicle Identification Number. ^ Retail Customer - Vehicle Leased Issue check to the customer at vehicle pickup (not GMAC or other financial institution) if valid proof of vehicle ownership documentation is available. Page 18049 Page 12471 Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Page 5710 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 2775 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 1875 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 3973 Note * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. 7. Position the camshaft sprocket (205) so the timing mark is in the 6 o'clock position. 8. Install the camshaft sprocket (205), timing chain (208), and bolt (206). 9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Page 2796 Page 1967 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 6376 Canister Purge Solenoid: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Page 7800 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 18525 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 16759 Disclaimer Page 4353 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Page 7817 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 6949 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 9222 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 3101 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 6136 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 5720 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 11495 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (Except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4/HP2) Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Page 6903 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 1879 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . Page 2225 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 19565 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 795 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 13492 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 10377 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 16618 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Component Views Page 13429 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 16101 Page 15339 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Page 1023 Page 12611 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Page 14307 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visuable damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) andTire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear) . * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications) . * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis) . * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications) . * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) . * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications) . Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. * The rear camber and caster is not adjustable. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications) . Page 4421 Drive Motor Generator Battery Control Module X2 (HP2) Page 5633 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Page 5858 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 1370 Page 19072 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Engine - Oil Consumption On Aluminum Block Engines Oil Pressure Regulator Valve: Customer Interest Engine - Oil Consumption On Aluminum Block Engines TECHNICAL Bulletin No.: 10-06-01-008B Date: March 07, 2011 Subject: Engine Oil Consumption on Aluminum Block Engines with Active Fuel Management (AFM) (Install AFM Oil Deflector and Clean Carbon from Cylinder) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2007-2009 GMC Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2009 Pontiac G8 GT Equipped with Aluminum Block V8 Engine with Active Fuel Management (AFM) (RPOs LC9, LH6, L76, LFA, L92) with Greater than 45,000 km (28,000 mi) Supercede: This bulletin is being revised to add the 2009 model year and new Correction information for the 2009 model year - left rocker arm cover replacement. Information has also been added after step 9. Please discard Corporate Bulletin Number 10-06-01-008A (Section 06 Engine/Propulsion System). Condition Some customers may comment about engine oil consumption of vehicles with higher mileage (approximately 48,000 to 64,000 km (30,000 to 40,000 mi). Verify that the induction system is assembled correctly and that there is no evidence that the engine has been ingesting dirty air due to a mis-assembled induction system. Also verify that the PCV system is functioning properly. If diagnostic procedures indicate that oil consumption is piston /piston ring related, verify that oil consumption is less than 3,000 km (2,000 mi) per liter/quart. If these conditions are met and oil consumption is less than 3,000 km (2,000 mi) per liter/quart, perform the service indicated in this bulletin. Cause This condition may be caused by oil spray that is discharged from the AFM pressure relief valve within the crankcase. Under most driving conditions and drive cycles, the discharged oil does not cause a problem. Under certain drive cycles (extended high engine speed operation), in combination with parts at the high end of their tolerance specification, the oil spray quantity may be more than usual, resulting in excessive deposit formation in the piston ring grooves, causing increased oil consumption. Correction 2009 Vehicles Only Important This left rocker arm cover is NOT to be used on 2007-2008 vehicles because of the calibration of the PCV orifice being different in 2007-2008. A new left rocker arm cover has been released for 2009 engines. Technicians should replace the left rocker arm cover with GM P/N 12642655. This rocker arm cover has relocated PCV drain holes that prevents PCV pullover into the intake manifold. Refer to SI for Valve Rocker Arm Cover Replacement - Left Side. 2008-2007 Vehicles Only To correct this condition, perform the piston cleaning procedure as described in this document, and install a shield over the AFM pressure relief valve per the procedure outlined in this document. Monitor oil consumption after this repair to ensure oil consumption has improved to acceptable levels. If this repair does not correct the condition, it may be necessary to replace the piston assemblies (piston and rings) with new parts. Important It is critical in this cleaning process that the engine/fuel injector cleaner remain in the cylinders for a minimum of 2.5 hours to fully clean the components. The cleaner solution must be removed before a maximum of three hours. 1. Verify the oil consumption concern following Corporate Bulletin Number 01-06-01-011F. If oil consumption is found, continue on with this bulletin. 2. Remove the spark plugs and ensure that none of the pistons are at top dead center (TDC). 3. Clean the pistons by putting 118-147 ml (4-5 oz) of Upper Engine and Fuel Injector Cleaner, GM P/N 88861802 (in Canada, use 88861804), in each cylinder. Allow the material to soak for at least 2.5-3.0 hours, but no more than three hours and then remove the cleaner. A suggested method Page 7207 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12466 Page 5743 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13177 Fuse Block - Auxiliary X2 (HP2) Page 3598 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 5790 Page 9681 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 7816 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12755 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Page 5686 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20428 Page 14932 Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 19166 Tailgate Shock / Support: Service and Repair Pickup Box Endgate Cable Bolt Replacement Pickup Box Endgate Cable Bolt Replacement OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 8646 Page 10056 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 20005 Page 11944 Page 2996 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 13169 Fuse Block - I/P X4 Page 4486 2. Obtain a revised wiring harness clip (Warranty Parts Center (WPC) # 577) from the WPC. Refer to Parts Information below. 3. Insert the motor harness (minus the two separate brown wires) into the revised wiring harness clip. 4. Position the two brown wires into the access slot (1) located on the internal side of the wiring harness clip. 5. Engage the locking tab (1) to retain the harness within the clip. 6. Install the wiring harness clip back into the motor housing. The drive motor is now ready to be installed into the transmission case. Parts Information To obtain the revised wiring harness clip, fax the form included in this bulletin to the GM Warranty Parts Center (WPC). Request WPC#577 for the wiring harness clip. Brake Pad and Rotor Burnishing Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 5722 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 14164 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 10381 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 15357 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Page 17035 Object Alarm Sensor - Right Rear Corner (UD7) Object Alarm Sensor - Right Rear Middle (UD7) Page 13765 X300 Chassis Harness to Engine Harness (4.8L/5.3L/6.0L/6.2L) Page 7228 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 18542 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Page 9909 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. Page 4578 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 6697 1 - Fuel Injector 2 2 - Turbocharger Vane Position Sensor 3 - Fuel Injector 4 4 - Fuel Rail Pressure (FRP) Sensor 5 - Fuel Injector 6 6 - Fuel Injector 8 7 - Glow Plug 8 8 - Glow Plug 6 9 - Engine Oil Pressure (EOP) Sensor 10 - Engine Oil Level (EOL) Switch 11 - Glow Plug 4 12 - G106 13 - G102 14 - Glow Plug 2 Top of the Engine Components (Diesel) Page 8166 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 19619 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Head Restraint Replacement Head Rest: Service and Repair Head Restraint Replacement Head Restraint Replacement Page 8883 Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 9252 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Page 13236 Junction Block - Right I/P (Wire Entry) Page 7273 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 12445 Junction Block - Left I/P X12 (except MEX) Page 8530 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 374 Page 13876 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 10277 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 5046 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 14154 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1070 Component Locations Hazard Flasher Relay: Component Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 14187 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 15276 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 12646 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Page 14264 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 11851 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 6823 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank to 2.5 Nm (22 lb in) . 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 7827 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 20485 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5340 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 4203 Page 10154 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Page 4156 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 15069 Page 8841 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 3851 15. Install the right side transmission cover bolt (2). Tighten the bolt to 12 Nm (106 lb in). 16. If reusing the old oil pan remove the old oil filter and install a NEW oil filter. 17. Lubricate the NEW oil filter seal with clean engine oil. 18. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). Page 12119 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Specifications Compressor Clutch: Specifications Air Gap ................................................................................................................................................ ................................. 0.35-0.65 mm (0.014-0.026 in) Page 1491 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 8375 Disclaimer Page 11116 Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the master cylinder reservoir cap and diaphragm. 4. Mark the location of the master cylinder brake pipe fittings (1). 5. Disconnect the master cylinder brake pipe fittings. 6. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 7. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 8. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 10. Press and release the brake pedal as far as it will travel several times. With the aid of an assistant, observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 11. Continue to press and release the brake pedal until fluid flows freely from the ports with no evidence of air bubbles. 12. Remove the transparent hoses from the master cylinder reservoir. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 13. Install the master cylinder brake pipe fittings, noting their location and tighten the fittings to 30 Nm (22 lb ft) . 14. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Master Cylinder Replacement (RHD) )Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Master Cylinder Replacement (Vacuum Boost)) . 15. Install the master cylinder reservoir cap and diaphragm. Page 13421 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics) . Page 17239 Auxiliary Body Control Module (XBCM) X1 (EXP) Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 6480 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 Nm (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 4577 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 5027 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 1940 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Page 19244 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Page 9357 2. Install the upper differential carrier assembly bushing by performing the following steps: 1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. 2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore. 3. Install the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . Page 4313 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 14345 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Page 18690 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 2709 Junction Block - Left I/P X1 (except MEX) Page 12881 For vehicles repaired under warranty, use the table. Disclaimer Page 14350 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 5272 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 7906 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 14417 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 12351 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11921 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 13168 Fuse Block - I/P X3 Page 10078 Input Shaft Seal Replacement Input Shaft Seal Replacement MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Torque Converter: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 9022 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 9925 Transfer Case Actuator: Locations MP 3023/3024-NQH - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 12271 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Right Side of the I/P Components Page 19416 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 12262 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Engine Harness Routing - Left Side (4.3L) Page 20272 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 17772 Disclaimer Page 11841 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6727 Fuel Pump Relay: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 18700 For vehicles repaired under warranty, use the table. Disclaimer Page 1752 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 15302 Page 7027 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9815 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1942 Page 11001 General Diagnostics/Brake System Internal Leak Test) andBrake Pedal Travel Measurement and Inspection (Non-Hybrid) (See: Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection)Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) (See: Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection) . 73. If internal leaks are found, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) ( See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 74. If the brake pedal travel exceeds specification and there is no damage to the pedal system or pushrod, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul )Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 75. Turn the ignition switch to ON, without starting the engine. Observe if the brake system warning lamp remains illuminated. 76. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until the brake system is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . 77. Start the engine. 78. Firmly apply the brake pedal several times. Observe the brake pedal feel. 79. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. 80. Drive the vehicle to a speed above 13 km/h (8 mph) to allow ABS initialization to occur. Observe the brake pedal feel. 81. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 8039 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 10587 Disclaimer Page 27 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 15050 Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 637 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 6565 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 5952 Body Control Module (BCM) X4 Page 1923 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 7189 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 19973 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 3505 Note Make sure that the pushrods seat properly to the ends of the rocker arms. DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. Cylinders 2, 4, 6 and 8 are the right bank. 6. Rotate the crankshaft until the number one piston is at top dead center (TDC) of the compression stroke. In this position, the number one cylinder rocker arms will be off lobe lift. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. With the engine in the number one firing position, tighten the following rocker arm bolts: * Tighten cylinders 1, 2, 7 and 8 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 1, 3, 4 and 5 intake valve rocker arm bolts to 30 Nm (22 lb ft). 8. Rotate the crankshaft 360 degrees. 9. Tighten the following rocker arm bolts: * Tighten cylinders 3, 4, 5 and 6 exhaust valve rocker arm bolts to 30 Nm (22 lb ft). * Tighten cylinders 2, 6, 7 and 8 intake valve rocker arm bolts to 30 Nm (22 lb ft). 10. Install the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . 11. Install the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . Page 13827 X176 Inline Harness Connector End Views Page 12575 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 8066 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 13318 Page 8088 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 17782 Disclaimer Page 11305 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 8309 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10089 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 9578 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Remove the rear propeller shaft from the rear axle and the center support bearing. Note Step 6 is for those vehicles that have a slip yoke from the transmission from transfer case to the propeller shaft. 6. Reference mark the transmission or the transfer case (1), propeller shaft slip yoke (2), universal bearing cap (3), and the propeller shaft (4). Note Step 7 is for those vehicles that have the yoke attached to the output shaft. Page 14193 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13833 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Headliner Harness (UE1/U3U/UVB) Page 9891 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 18100 Memory Seat Module (MSM) X7 (AN3) Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Page 20051 Page 530 Page 11425 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 14634 Disclaimer Page 4747 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Specifications Firing Order: Specifications Ignition System Specifications Page 13742 X202 Page 8578 Director, Customer and Relationship Services 09241 Page 15898 Disclaimer Page 2970 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 10326 Page 10945 If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer toBrake Rotor Refinishing (See: Brake Rotor Refinishing) . After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator,J-45101 - Hub and Wheel Runout Gage , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) . 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Refinishing Brake Rotor Refinishing Special Tools * J-41013 - Rotor Resurfacing Kit * J-42450-A - Wheel Hub Resurfacing Kit Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement) . Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Note If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Note Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. Page 2894 Component Parts Page 8193 Page 19518 Page 12481 Fuse Block - Underhood X6 Page 6457 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure Note Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove EVAP canister vent solenoid clip (1) from the chassis EVAP line. 3. Remove the EVAP canister vent solenoid pipe from the clip (2) on the chassis EVAP line. 4. Remove the EVAP canister vent solenoid pipe from the clips (3) on the brake pipes. 5. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid. Page 4924 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 3499 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service and Repair/Overhaul) . Installation Procedure Note When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Page 7194 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 10358 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 6449 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 3927 Intake Manifold: Service and Repair Upper Intake Manifold Cover Replacement Upper Intake Manifold Cover Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: ) . 2. Reposition the brake booster vacuum hose clamp at the intake manifold. 3. Remove the brake booster vacuum hose from the intake manifold nipple. 4. Remove the upper intake manifold cover nut. 5. Remove the upper intake manifold cover. Installation Procedure Page 1338 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 13071 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. TheJ 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. TheJ 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. IfJ 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 16469 Page 17141 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring recepticle (4). Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 16126 Keyless Entry Transmitter: Service and Repair Remote Control Door Lock Transmitter Programming Next Available Slot Note * On some vehicles, keyless entry transmitters may also be programmed using the driver information center (DIC). Refer to the vehicle owners manual for information. * All transmitters which are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle are not learned at this time, they will become inoperative and require additional programming. * Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. This procedure will program keyless entry transmitters in sequential order. If two transmitters are currently learned to the vehicle as transmitters 1 and 2, using this procedure will learn the next transmitter are transmitter 3, and so on. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. 2. Select Next Available Slot. The vehicle chime will sound two times to indicate programming mode has been entered. Follow the on-screen instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm the programming. 3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF, exit the vehicle, and operate the transmitter functions in order to verify correct system operation. Invalidate All Fobs Note * On some vehicles, keyless entry transmitters may also be programmed using the driver information center (DIC). Refer to the vehicle owners manual for information. * All transmitters which are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle are not learned at this time, they will become inoperative and require additional programming. * Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. This procedure will first erase all known keyless entry transmitters. After all transmitters are erased, the procedure will begin to program keyless entry transmitters in sequential order, beginning with transmitter 1. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. 2. Select Invalidate All Fobs. This will erase all learned transmitters and prepare the RCDLR to learn new transmitters. Follow the on-screen instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm the programming. 3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF, exit the vehicle, and operate the transmitter functions in order to verify correct system operation. Transmitter Slot Programming Note The keyless entry transmitter used in the Advance 2 Way Remote Start System is unique to the system. When servicing or replacing a transmitter, ensure that the correct transmitter is used. The correct transmitter part number can be found in the Accessory section of the parts catalog. Attempting to replace an Advance 2 Way Remote Start transmitter with a regular service part may result in a failure to program the transmitter. Transmitter slot programming allows a single transmitter to be programmed into a specific slot without affecting any of the other programmed transmitters. By using slot programming, the transmitter originally programmed to a specific slot is erased and the new transmitter learned in its placed. 1. Install a scan tool. 2. Turn ON the ignition with the engine OFF. 3. With the scan tool, select Body. 4. Select Remote Control Door Lock Receiver (RCDLR). 5. Select Module Setup. 6. Select Program Key Fobs. 7. Select the key fob desired to be programmed. 8. Follow the scan tool on screen instructions. Page 654 Auxiliary Body Control Module (XBCM) X2 (EXP) Page 19436 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13569 Junction Block - Right I/P X3 Page 10104 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 13242 Junction Block - Right I/P X4 Page 4467 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 17395 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 10845 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Page 12473 Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 7925 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 18888 Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the MSM, CCSM, and door lock/window switch replacement, setup, and programming Page 20666 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Page 15303 Page 11073 Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Page 13461 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15419 A/C Refrigerant Pressure Sensor (Diesel) A/C Refrigerant Pressure Sensor (Gas Except HP2) Page 12044 Fuse Block - Underhood X6 Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 8024 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Page 14295 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 1813 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 11632 Module Circuit Function Icons A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 10433 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 1682 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 2731 Page 9362 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500 HD, and 3500 HD SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Page 17331 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 6973 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 20721 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15040 Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 8174 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 13041 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 2801 Engine - Oil Consumption On Aluminum Block Engines Oil Pressure Regulator Valve: All Technical Service Bulletins Engine - Oil Consumption On Aluminum Block Engines TECHNICAL Bulletin No.: 10-06-01-008B Date: March 07, 2011 Subject: Engine Oil Consumption on Aluminum Block Engines with Active Fuel Management (AFM) (Install AFM Oil Deflector and Clean Carbon from Cylinder) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2007-2009 GMC Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2009 Pontiac G8 GT Equipped with Aluminum Block V8 Engine with Active Fuel Management (AFM) (RPOs LC9, LH6, L76, LFA, L92) with Greater than 45,000 km (28,000 mi) Supercede: This bulletin is being revised to add the 2009 model year and new Correction information for the 2009 model year - left rocker arm cover replacement. Information has also been added after step 9. Please discard Corporate Bulletin Number 10-06-01-008A (Section 06 Engine/Propulsion System). Condition Some customers may comment about engine oil consumption of vehicles with higher mileage (approximately 48,000 to 64,000 km (30,000 to 40,000 mi). Verify that the induction system is assembled correctly and that there is no evidence that the engine has been ingesting dirty air due to a mis-assembled induction system. Also verify that the PCV system is functioning properly. If diagnostic procedures indicate that oil consumption is piston /piston ring related, verify that oil consumption is less than 3,000 km (2,000 mi) per liter/quart. If these conditions are met and oil consumption is less than 3,000 km (2,000 mi) per liter/quart, perform the service indicated in this bulletin. Cause This condition may be caused by oil spray that is discharged from the AFM pressure relief valve within the crankcase. Under most driving conditions and drive cycles, the discharged oil does not cause a problem. Under certain drive cycles (extended high engine speed operation), in combination with parts at the high end of their tolerance specification, the oil spray quantity may be more than usual, resulting in excessive deposit formation in the piston ring grooves, causing increased oil consumption. Correction 2009 Vehicles Only Important This left rocker arm cover is NOT to be used on 2007-2008 vehicles because of the calibration of the PCV orifice being different in 2007-2008. A new left rocker arm cover has been released for 2009 engines. Technicians should replace the left rocker arm cover with GM P/N 12642655. This rocker arm cover has relocated PCV drain holes that prevents PCV pullover into the intake manifold. Refer to SI for Valve Rocker Arm Cover Replacement - Left Side. 2008-2007 Vehicles Only To correct this condition, perform the piston cleaning procedure as described in this document, and install a shield over the AFM pressure relief valve per the procedure outlined in this document. Monitor oil consumption after this repair to ensure oil consumption has improved to acceptable levels. If this repair does not correct the condition, it may be necessary to replace the piston assemblies (piston and rings) with new parts. Important It is critical in this cleaning process that the engine/fuel injector cleaner remain in the cylinders for a minimum of 2.5 hours to fully clean the components. The cleaner solution must be removed before a maximum of three hours. 1. Verify the oil consumption concern following Corporate Bulletin Number 01-06-01-011F. If oil consumption is found, continue on with this bulletin. 2. Remove the spark plugs and ensure that none of the pistons are at top dead center (TDC). 3. Clean the pistons by putting 118-147 ml (4-5 oz) of Upper Engine and Fuel Injector Cleaner, GM P/N 88861802 (in Canada, use 88861804), in each cylinder. Allow the material to soak for at least 2.5-3.0 hours, but no more than three hours and then remove the cleaner. A suggested method Page 6808 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 16415 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Auxiliary Battery Tray Replacement Battery Tray: Service and Repair Auxiliary Battery Tray Replacement Auxiliary Battery Tray Replacement Page 19032 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Page 17315 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can Page 11029 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . Rear Brake Caliper Overhaul (JH6, JH7) Page 5751 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10224 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 8778 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 540 Page 18211 Memory Seat Module (MSM) X6 (AN3) Page 735 Engine Control Module (ECM) X1 (HP2) Page 10940 Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing) . * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) . If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * J-39544-KIT - Torque-Limiting Socket Set , or equivalent * J-45101-100 - Conical Brake Rotor Washers Page 3635 5. Apply threadlock to the threads of the ignition coil bracket studs. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . 6. Position the ignition coil bracket (719) onto the rocker cover. 7. Install the ignition coil bracket studs (720). Tighten the studs to 12 Nm (106 lb in). 8. Install the spark plug wires (724) to the ignition coils. 9. Position the engine harness, as necessary. 10. Install two engine harness clips (4) to the ignition coil bracket studs. 11. Connect the engine harness electrical connector (1) to the ignition coil wire harness. 12. Install the CPA retainer (2). 13. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . Page 19352 Page 16989 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 19600 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 2125 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 17041 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Page 8017 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case High/Low Shift Fork Pad 11 - Transfer Case High/Low Shift Fork 12 - Transfer Case High/Low Shift Fork Spring Assembly 13 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 14 - Transfer Case Two/Four Wheel Drive Actuator Cam Spacer 15 - Transfer Case Two/Four Wheel Drive Actuator Cam 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case High/Low Shift Fork Pin 18 - Transfer Case Actuator Shaft Gear 19 - Transfer Case Rear Output Shaft Assembly 20 - Transfer Case Front Output Shaft Drive Chain Assembly 21 - Transfer Case Front Output Shaft Drive Sprocket 22 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly Page 20302 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 14971 Page 20349 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 7408 Transfer Case Actuator: Locations Powertrain Component Views Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 1368 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 15969 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 5480 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10470 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case Two/Four Wheel Drive Actuator Cam 15 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 16 - Transfer Case High/Low Shift Fork 17 - Transfer Case High/Low Shift Fork Pads 18 - Transfer Case High/Low Shift Fork Spring Assembly 19 - Transfer Case High/Low Shift Fork Pin 20 Transfer Case Control Actuator Shaft 21 - Transfer Case Rear Output Shaft 22 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 23 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 24 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 25 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring 26 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring 27 - Transfer Case Front Output Shaft Drive Chain Assembly 28 - Transfer Case Front Output Shaft Drive Sprocket 29 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 30 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 31 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 32 Transfer Case Oil Pump Assembly 33 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 34 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 35 - Transfer Case Rear Output Shaft Rear Bearing Assembly 36 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 37 - Transfer Case Oil Pump Suction Pipe Seal 38 - Transfer Case Oil Pump Suction Pipe 39 - Transfer Case Front Output Shaft Rear Bearing Assembly 40 - Transfer Case Front Output Shaft Driven Sprocket Spacer 41 - Transfer Case Front Output Shaft Driven Sprocket 42 - Transfer Case Front Output Shaft Hole Plug 43 - Transfer Case Front Output Shaft 44 Transfer Case Front Output Shaft Front Bearing Assembly Page 7302 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 16951 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 17132 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 16170 Cellular Phone Microphone: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 3058 Junction Block - Right I/P X2 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 12637 X214 Inline Harness Connector End Views Page 3923 26. Position and install the PCV hose to the intake manifold fitting. 27. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 28. Connect the EVAP canister purge tube (1) quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 87 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 1796 Manifold Absolute Pressure (MAP) Sensor (Gas Except 4.3L) Page 18804 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 737 Engine Control Module (ECM) X1 (LY6) Page 4926 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 13616 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 4842 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 19391 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 13770 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 1307 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Page 1524 Drive Motor Generator Battery Control Module X5 (HP2) Page 11943 Testing and Inspection Fan Clutch: Testing and Inspection Fan Clutch Diagnosis Page 3653 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair) . Page 12589 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Page 13783 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 7959 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12043 Page 17081 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 14254 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 8930 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 2059 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 16980 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13311 Page 20049 Page 9103 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 13025 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Locations Acceleration/Deceleration Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 9349 26 - Front Differential Case 27 - Differential Pinion Gear Shaft Lock Bolt 28 - Differential Side Bearing 29 - Differential Side Bearing Cup 30 - Front Differential Ring Gear 31 - Front Differential Half Carrier Location Pin 32 - Front Differential Bearing Adjuster Nut Lock 33 - Differential Pinion Gear 34 - Differential Pinion Gear Thrust Washer 35 - Differential Side Gear Thrust Washer 36 Differential Side Gear 37 - Differential Pinion Gear 38 - Differential Pinion Gear Thrust Washer 39 Front Differential Side Gear Spacer 40 - Front Differential Side Gear 41 - Front Differential Side Gear Thrust Washer 42 - Front Differential Drive Pinion Gear 43 - Differential Drive Pinion Gear Bearing Shim 44 - Front Differential Drive Pinion Gear Inner Bearing 45 - Front Differential Drive Pinion Gear Inner Bearing Cup 46 - Front Differential Drive Pinion Gear Bearing Spacer 47 - Front Differential Carrier Bushing 48 - Front Differential Carrier 49 - Front Differential Bearing Adjuster Nut Lock 50 - Bolt 51 - Front Differential Drive Pinion Gear Yoke Nut 52 - Front Differential Drive Pinion Gear Thrust Washer 53 - Front Differential Drive Pinion Gear Yoke 54 - Front Differential Drive Pinion Gear Bearing Dirt Deflector 55 - Front Differential Drive Pinion Gear Seal 56 - Front Differential Drive Pinion Gear Outer Bearing Cup 57 - Front Differential Drive Pinion Gear Outer Bearing 58 - Front Differential Carrier Bushing 59 - Differential Bearing 60 - Front Differential Bearing Adjuster O-Ring Seal 61 - Front Differential Bearing Adjuster 62 - Front Drive Axle Inner Shaft Seal 63 - Front Drive Axle Inner Shaft Retaining Ring 64 - Front Drive Axle Inner Shaft 65 Front Differential Carrier Vent 66 - Fuel and Oil Resistant Hose 67 - Clamp 68 - Front Differential Carrier Vent Hose Connector 69 - Front Differential Carrier Oil Drain Plug 70 - Front Differential Carrier Oil Drain Plug Washer 71 - Front Differential Carrier Oil Fill Plug 72 - Front Differential Carrier Oil Fill Plug Washer Page 12332 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 15095 Page 15265 Page 20531 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 13813 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Page 4424 Drive Motor Generator Battery Control Module X5 (HP2) Page 18305 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the glass panel stalls at the hard stop, then moves slightly forward. This position is called the soft stop or full open position. 2. Release the switch. 3. Press and hold the open switch within 6 seconds. 4. Hold the open switch until the glass panel moves to the closed position and stops. 5. Release the switch. Page 18458 Memory Seat Module (MSM) X4 (AN3) Page 6024 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 8052 Page 15126 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Locations Front Door Latch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 8807 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9485 Note Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. Page 9112 Page 12523 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 7244 Emissions - MIL ON/DTC P0446 Stored In ECM Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 5869 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 18477 Memory Seat Module (MSM) X7 (AN3) Page 18008 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 10361 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3986 11. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 12. Install a NEW CMP actuator valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Body - Incorrect Sun Visor Label Child Seat: Customer Interest Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 4116 Page 13047 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 7924 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3562 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5670 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 18220 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 8808 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 5518 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 9328 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Page 17386 Page 7320 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 13850 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 11511 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Page 12085 Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 2189 Window Switch - Left Rear (Crew Cab with A31/Extended Cab with ABV) Page 17612 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 12507 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 4879 Engine Control Module (ECM) X1 (Gas Except 4.3L/LY6/HP2) Page 14368 Note Discard the steering linkage shock absorber nut. 4. Remove the steering linkage shock absorber bolt (2) and nut (3). 5. Remove the steering linkage shock absorber (1) from the vehicle. 6. Inspect the following parts: * The steering linkage shock absorber for leaks and damage * The steering linkage shock absorber bolt for damage or corrosion Installation Procedure Note Use new steering linkage shock absorber nuts. Page 6127 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 6145 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11677 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 17895 Passenger Assist Handle: Service and Repair Front Assist Handle Replacement Front Assist Handle Replacement Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 19762 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Diagrams Battery Cooling Fan Relay: Diagrams Component Connector End Views Generator Battery Vent Fan (HP2) Generator Battery Vent Fan Relay (HP2) Page 15804 Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Crew Cab) Rear Seat Center Belt Buckle Replacement (Crew Cab) Page 8127 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11426 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 10073 1. Using the J 42738 , install the input shaft seal. 2. Install the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 Transfer Case/Transfer Case Assembly Replacement) . Page 7337 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 8852 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 20396 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 18314 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 10496 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8350 For vehicles repaired under warranty, use the table. Disclaimer Page 7772 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 7136 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 18126 For vehicles repaired under warranty, use the table. Disclaimer Page 13405 Switches and Relays Component Locations Power Seat Motor: Component Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Page 20048 A/T Controls - Snapshot Data Upload Information Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information INFORMATION Bulletin No.: 07-07-30-010B Date: June 19, 2009 Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using TIS Software Models: 2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models) 2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section 07 - Transmission/Transaxle). Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool platform and software will be required for use with all GM Global Architecture (Global A) vehicles beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R) communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number 09-00-89-019 (Introduction of New Global Diagnostic System (GDS)). This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and upload it to a computer. The procedure is written for an automatic transmission data snapshot on a Saturn AURA, but is similar for all applications. This procedure is written with the assumption the user has a basic understanding of how to use a Tech 2(R) already. Capturing a Snapshot of the Vehicle Data Stream 1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen. 3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the scan tool's display. Bolded selections are vehicle specific. - Select "2007" - Select "Passenger Car (F0)" - Select "Saturn" Page 11493 1 - Wheel Speed Sensor (WSS) -Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) -Left Front (JL4/JF3/JF7/JH6/JH7) Front Frame and Underbody Components - 2 of 2 Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (with Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling , or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. Test Procedure 1. Test the fuel composition usingJ 44175 Fuel Composition Tester and J44175-3 Instruction Manual. 2. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 3. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank . 4. Test the fuel composition. 5. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Page 19481 Page 7642 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7531 Page 17923 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17575 8. Install the rear sliding window stops (1) in place and fully seated. 9. Cycle the rear sliding window to the fully closed position. 10. Install the lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 11. Inspect the rear sliding window for proper operation. 12. Clean the window. Page 2949 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ..................................................... 240 Nm (177 lb ft) Page 6086 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 3961 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 2990 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 19905 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 9063 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7573 Page 11059 Brake Hose/Line: Service and Repair Front Brake Hose Replacement Front Brake Hose Replacement (JH6, JH7) Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 3754 3. Install the oil pan. Refer to Oil Pan Replacement (4WD) (See: Oil Pan/Service and Repair)Oil Pan Replacement (2WD) (See: Oil Pan/Service and Repair) . Page 15311 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 12376 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 1262 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 Page 14464 Ball Joint: Testing and Inspection Ball Joint Inspection (Upper Ball Joint) Ball Joint Inspection (Upper Ball Joint) Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 4. Support the lower control arm with a floor stand or jack, as far outboard as possible. 5. If a seal is cut or torn, replace the ball joint. 6. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) ( See: Control Arm/Service and Repair/Upper Control Arm Replacement) . 7. Check the wheel bearing for looseness in the wheel bearing is present. Refer to Wheel Bearings Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis) . 8. Check the upper ball joint for vertical looseness. 9. Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded. 10. Install and position the dial indicator fromJ 8001 against the rim of the upper ball joint. 11. Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the upper ball joint. 12. Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is too high, replace the upper control arm. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement) . Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . Note Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. Page 12067 Page 1014 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 7140 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9233 11. Remove the control valve channel plate (1). Caution: Do not use the old spacer plate. Install a NEW spacer plate. Reusing an old spacer plate may cause internal transmission leaks and transmission damage. 12. Remove the control valve body spacer plate with gasket assembly (2). 13. Remove the fluid pump ball check valve (3) from the control valve upper body assembly (4). Installation Procedure 1. Install the fluid pump ball check valve (3) to the control valve upper body assembly (4). Caution: Do not use the old spacer plate. Install a NEW spacer plate. Reusing an old spacer plate may cause internal transmission leaks and transmission damage. 2. Install the control valve body spacer plate with gasket assembly (2). 3. Install the control valve channel plate (1). Page 19928 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 188 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 20180 Page 5326 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Ignition System/Specifications) 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the spark plug. Tighten the plug to 15 Nm (11 lb ft). Hybrid - Reinstalling Hybrid Transmission Drive Motors Drive Motor Power Cable: Technical Service Bulletins Hybrid - Reinstalling Hybrid Transmission Drive Motors INFORMATION Bulletin No.: 10-06-122-001 Date: November 03, 2010 Subject: Reinstalling Hybrid Transmission Drive Motors On 2-Mode Hybrid Full Size Trucks Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with 2ML70 Hybrid Transmission (RPO M99) All Built Prior to VIN Breakpoint 10020698 During service of a 2-Mode hybrid drive motor, the motor harness can easily be damaged if the appropriate precautions are not used. When reinstalling a drive motor, sharp edges of the transmission case access opening may chafe or cut the harness when the drive motor is fed through the case opening. Recommendation Use the procedure and parts below to protect the drive motor harness PRIOR to reinstallation into the transmission case. 1. Remove the black plastic wiring harness clip (1) from the motor casing and pull the harness out of the clip, exposing the drive motor wires (2). Page 16518 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 14040 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 11722 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 4705 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 18559 Page 12202 Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 10874 Brake Pad: Service and Repair Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JD9) Page 3901 37. Remove the throttle body bolts/nuts. 38. Remove the throttle body. 39. Remove and discard the throttle body gasket. 40. Remove the fuel rail bolts. Note Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 41. Remove the fuel rail. 42. Remove and discard the fuel injector lower O-ring seals. Installation Procedure Page 2725 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 19621 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 12334 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 19246 Front Door Weatherstrip: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Front Side Door Upper Hinge and Lower Hinge Replacement Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 10141 Clutch Components 1 - Transfer Case Rear Output Shaft 2 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 3 - Transfer Case Control Lever 4 - Transfer Case Control Actuator Lever Bearing Assembly 5 - Transfer Case Control Actuator Lever Ball (Qty: 3) 6 - Transfer Case Control Actuator Lever Assembly 7 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 8 - Transfer Case Control Actuator Lever Washer 9 - Transfer Case Four Wheel Drive Clutch Pressure - Apply Plate Page 5761 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 20798 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 8235 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 7606 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. Page 1727 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 17180 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 8390 Director, Customer and Relationship Services 09241 Page 14901 Page 11635 Page 1054 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Page 1139 Object Alarm Sensor - Right Rear Corner (UD7) Object Alarm Sensor - Right Rear Middle (UD7) Page 2457 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 12669 X350 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) Page 3982 3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. 4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. Page 5796 High Speed Bus - 1 of 6 (except MEX/HP2) Page 10260 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13260 Fuse Block - I/P X4 Page 15080 7. Install the lower bolts to the hood latch support bracket and tighten to 9 Nm (80 lb in) . 8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to Radiator Support Replacement () . Tighten the nut to 16 Nm (12 lb ft). 9. Install radiator support bracket bolts (1). 10. Install the fascia. 11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) ()Refrigerant Recovery and Recharging (HP2) () . 12. Leak test the fittings of the component using the J 39400-A . Page 13007 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 12585 1 - X800 2 - Door Handle 3 - Door Frame Brake Clutch Harness Routing Page 5591 Locations Rear Door Window Glass: Locations Harness Routing Views Sliding Rear Window Jumper Harness Routing (A48) 1 - X320 2 - Rear Window 3 - J336 (except C49) 4 - J335 (except C49) Left and Right Hip Lamp Harness Routing (R05) Page 18261 Seat Climate Control Module X3 (KB6) Page 20219 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 12385 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2905 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 18045 Page 7866 Page 2090 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 3056 Page 13692 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 1158 Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Page 1719 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 2754 Page 6801 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Page 7217 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 1901 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 6525 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 3748 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to theMaster Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 11757 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 9013 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Exhaust - Muffler Heat Shield Buzz During Operation Heat Shield: Customer Interest Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Tire Monitor System - Tire Pressure Light Stays ON Door Module: All Technical Service Bulletins Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Page 7360 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 11204 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 19463 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 13533 Page 1497 Drive Motor Generator Battery Control Module X4 (HP2) Page 7967 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Locations Seat Memory Switch: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 9109 Page 4589 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 11524 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 4122 Page 12625 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 13320 Fuse Block - Underhood X3 Page 20069 Hazard Flasher Relay: Diagrams Component Connector End Views Emergency Vehicle Roof Lamp Relay (5Y0) Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Page 6864 Page 9435 14. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 15. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. 16. Remove the oil seal using a suitable seal removal tool. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution) . 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 9028 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Inspection and Cleaning Drain Hose Routing Note If the headliner is wet DO NOT remove any interior trim. Do the Plugged Drain Hose test first. A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. The front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. The front hoses are installed in a rubber grommet and retained by clips. 2. The rear drain hoses are routed through the rear pillars and out of the rocker panel. In some vehicle the drain hoses are routed out through the metal roof slots and routed to the lower wheelhouse to drain out of the vehicle. The rear hoses are installed in a rubber grommet and retained by clips. Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Warning Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Sunroof Housing Front Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Front Drain Hose Replacement) orSunroof Housing Rear Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Rear Drain Hose Replacement) . 6. Remove the blockage using the following steps. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Page 6863 Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas Except LU3/LY6) Page 20119 Page 598 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Page 1637 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 16079 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 7179 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 16037 Page 8842 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2866 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Fuse Block Jumper Harness Routing (9L4) Page 3833 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Place a suitable drain pan under the oil pan drain plug. 3. Remove the oil pan drain plug (430). 4. Allow the oil pan to drain completely. 5. Re-install the oil pan drain plug until snug. 6. Remove the drain pan from under the vehicle. 7. Disconnect the engine harness electrical connector (1) from the oil level sensor. Page 19261 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 10406 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15492 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 13438 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 14640 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8138 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 1946 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 14165 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 3471 16. Remove the J 42386-A (1) and bolts. 17. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair) . 18. Install the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair) . 19. Install the radiator support. Refer to Radiator Support Replacement () . Page 12985 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 18790 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12139 Fuse Block - I/P Top View Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Page 15845 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 14332 Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Page 17864 Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Page 4622 Drive Motor Generator Battery Control Module X4 (HP2) Page 7317 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13711 Page 7116 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12275 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 5959 Page 19562 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 2961 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 9504 Note Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Page 18225 Page 12169 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 7240 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC/MYD/M99) Control Solenoid Valve Assembly X2 (MYC/MYD) Page 2315 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 17703 1. Position the oil skid plate on the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the oil skid plate mounting bolts and tighten to 28 Nm (21 lb ft) . Page 8767 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 6685 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: All Technical Service Bulletins Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2710 Page 17332 Front Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (Except AU3) Page 353 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 1310 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Power Brake Booster Vacuum Sensor Replacement Removal Procedure 1. Disconnect the chassis wiring harness electrical connector (1) from the brake booster vacuum sensor. 2. Remove the brake booster vacuum sensor from the brake booster. 3. Remove the brake booster vacuum sensor grommet from the brake booster. Installation Procedure Important: Lightly coat the brake booster vacuum sensor grommet with clean engine oil before installing the sensor. Page 15698 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 - G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Page 12442 Junction Block - Left I/P X9 (except MEX) Diagrams Rear Vision Camera: Diagrams Component Connector End Views Rearview Camera (SVA) Page 20279 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 19529 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 9448 18. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . 19. Lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with the two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 6. Using a hydraulic press and an appropriate tool, remove the pinion. Page 6800 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Page 17235 Page 20513 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 11060 Page 20495 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 4330 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Page 11856 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 13593 Fuse Block - Underhood X4 Page 10876 Brake Pad: Service and Repair Rear Disc Brake Pads Replacement (JH6, JH7) Rear Disc Brake Pads Replacement (JH6, JH7) Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LFA) engine, the park position for the CMP actuator and camshaft is 14.5 degrees after top dead center (ATDC), or 29 crankshaft degrees ATDC. The engine control module (ECM) can only command the CMP actuator to advance the valve timing from the park position, or retard the valve timing back to the park position. The total range of valve timing authority is 23 degrees camshaft rotation, or 46 degrees of crankshaft rotation. The control range is from the park position of 14.5 degrees camshaft, or 29 degrees crankshaft ATDC, to 8.5 degrees camshaft or 17 degrees crankshaft before top dead center (BTDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for CAM advance and a passage for CAM retard. The camshaft actuator is attached to the front of the camshaft, and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature, engine oil level, and aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostic The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control, DTC P0010 will set. Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 13884 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 10028 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 19280 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Page 7936 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Tail Lamp Bulb Replacement (Chevrolet) Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement (Chevrolet) Tail Lamp Bulb Replacement (Chevrolet) Page 17835 Front Floor Console Replacement (with RPO SLT) Front Floor Console Replacement (with RPO SLT) Page 15867 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Locations Coolant Level Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Diagrams Power Seat Control Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 15527 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 3894 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the oil pressure sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install a NEW washer (707) and the oil pressure sensor (706). Tighten the sensor to 35 Nm (26 lb ft). 3. Lubricate the O-ring seals with clean engine oil. 4. Install the O-ring seals (537) to the cover. 5. Set the engine valley cover (555) onto the engine. 6. Install the engine valley cover bolts (506). Tighten the bolts to 25 Nm (18 lb ft). 7. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: )Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: )Intake Manifold Replacement (LY2 and LY6) (See: ) . Page 6873 Page 17839 Roof Console Replacement Roof Console Replacement Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 19453 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12633 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (A48) Page 18966 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 12160 Page 572 Page 19209 Figure 4 - Top View - Rear Structure Figure 5 - GM Cargo Management Points Caution Overloading the vehicle may cause damage. Do not overload the vehicle. When you carry removable items, you may need to put a limit on how many people you carry inside your vehicle. Be sure to weigh your vehicle before you buy and install the new equipment. Remember not to exceed the Gross Axle Weight Rating (GAWR) of the front or rear axle. If the vehicle is damaged due to overloading, repairs would not be covered by the vehicle warranty. The load bearing structural information is also included in the Body Builder's manual at www.gmupfitter.com. Disclaimer Page 5864 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor (1). 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 12950 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 4057 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Page 18969 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 12506 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 12955 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 6141 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 9018 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 4022 1. Install the a NEW CMP actuator solenoid valve until snug. With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the CMP actuator solenoid valve. 1. Tighten the solenoid valve a first pass to 65 Nm (48 lb ft). 2. Tighten the solenoid valve a final pass and additional 90 degrees using J 45059 . 3. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 7185 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 4445 Battery Bus Module: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 2823 Fuse Block - Auxiliary X2 (HP2) Page 7845 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC/MYD/M99) Control Solenoid Valve Assembly X2 (MYC/MYD) Page 8010 Transfer Case Actuator: Locations MP 1625/1626-NQF - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 - Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor - O-Ring - Seal 15 - Transfer Case Rear Half 16 Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 22 - Transfer Case Two/Four Wheel Drive Actuator Assembly 23 - Transfer Case Two/Four Wheel Drive Actuator Seal Page 8823 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8155 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 5989 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 5337 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Roof Marker Lamp Replacement (Without SRW) Marker Lamp: Service and Repair Roof Marker Lamp Replacement (Without SRW) Roof Marker Lamp Replacement (Without SRW) Page 18063 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 11063 Brake Hose/Line: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Note Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visuable damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) andTire Diagnosis Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear) . * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications) . * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis) . * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering and Suspension/Steering/Specifications) . * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle) . * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications) . Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. * The rear camber and caster is not adjustable. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications) . Page 1082 Page 20534 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 3667 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11649 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 16158 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4017 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Page 3286 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 15799 Seat Belt Buckle: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Page 10558 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 19646 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 14406 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 3029 Fuse Block - Auxiliary X2 (HP2) Page 10681 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 13034 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 16674 Warranty Information (Saab U.S. Models) Disclaimer Page 2623 Page 1996 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17353 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab Upper) Door Striker Replacement (Extended Cab Upper) Removal Procedure Note If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the upper trim door upper striker cover (2). Pull straight downward for the trim cover to release, retained by retainer clips (1). 2. Remove the door upper striker bolts (3). 3. Remove the spacer, if equipped. 4. Remove the door upper striker (4). Installation Procedure Diagrams Safety Disconnect Impact Sensor: Diagrams Component Connector End Views High Voltage Circuit Impact Detection Sensor (HP2) Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 4590 Battery Bus Module: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 10943 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Note Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7) (See: Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7))Front Brake Rotor Replacement (JH6, JH7) (See: Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) and/orRear Brake Rotor Replacement (JD9) (See: Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Service and Repair/Rear Brake Rotor Replacement (JH7)) . 2. Using the J-42450-A - Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the J-41013 - Rotor Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 Conical Brake Rotor Washers (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Page 18906 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 990 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 2756 MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 5082 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 3044 Junction Block - Left I/P X4 (except MEX) Page 3413 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 12267 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Instrument Panel/Center Console Component Views Behind the I/P Components Page 15263 Page 7260 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9081 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13295 Page 17246 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Page 6247 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (4.3L) Manifold Absolute Pressure (MAP) Sensor (Diesel) Page 18920 Seat Climate Control Module X2 (KB6) Page 14930 Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 16309 Page 15694 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 603 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Page 5646 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 12576 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 19652 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Page 9455 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Tighten the wheel bearing adjusting nut using the J 2222-C . Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder and tighten the adjusting nut to 70 Nm (52 lb ft) . 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C . 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: * If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Note Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. * If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 11. Inspect the lubricant level and add, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . Page 11911 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 5594 Page 13641 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 20646 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 2126 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 16580 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 8459 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 20610 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 630 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 19376 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 1828 3. Connect the engine wiring harness electrical connector (7) to the HO2S. 4. Install the engine wiring harness electrical connector clip (6) to the fuel line clip. 5. Install the CPA retainer (4). 6. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Lower the vehicle. Page 5626 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 8090 View of the connector when released from the component. View of another type of Micro 64 connector. Page 485 Page 11925 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 13851 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) X300 Chassis Harness to Engine Harness (4.3L) Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 2237 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Page 12428 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 361 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Restraints - Seat Belt Latch Stop Button Availability Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11613 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 11419 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 9266 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Special Tools * J 24460-01 Cooling System Pressure Tester * J 42401 Radiator Cap/Surge Tank Test Adapter Pressure Cap Testing Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. Note Lubricate J-42401 and pressure cap o-rings with coolant and press cap to seat o-ring on J-42401 before turning to engage threads. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Page 13039 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Service and Repair Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 15592 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended/Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Page 4866 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8783 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 13733 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 3466 4. Remove the bolt from the front of the camshaft. Note The gasket surface on the engine block should be clean and free of dirt and/or debris. 5. Install the camshaft retainer (203) and bolts (204). Install the retainer with the sealing gasket facing the engine block. 6. Tighten the camshaft retainer bolts. * Tighten the first design hex head bolts (3) to 25 Nm (18 lb ft). * Tighten the second design TORX(R) head bolts (4) to 15 Nm (11 lb ft). Page 13495 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 17223 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 3133 Page 12610 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 20593 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 4618 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 2714 Junction Block - Left I/P X3 (except MEX) Page 10088 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12595 Page 7713 Page 1267 Seat Adjuster Switch - Passenger (AG2 without AN3) Page 1389 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 18869 Heated/Cooled Seat Module Power and Ground (KB6) Page 20452 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Locations Seat Heater Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 19586 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 1933 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Page 7288 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 11835 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 4419 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 6140 Page 10312 Switch Position Icons Page 18722 Seat Heater: Specifications Fastener Tightening Specifications Page 11247 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Diagrams Throttle Body: Diagrams Component Connector End Views Throttle Body (HP2/Early Production with 4.3L/4.8L/5.3L/6.0L/6.2L) Throttle Body (Late Production with 4.3L/4.8L/5.3L/6.0L/6.2L) Page 10162 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 4324 Disclaimer Page 11671 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 4444 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 1642 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 16382 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer 08-08-49-016C - END OF INFORMATION NEED Fuel Gauge Sender: Technical Service Bulletins 08-08-49-016C - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 08-08-49-016C Date: May 21, 2009 Subject: EI08347 - DTC P0463, Fuel Gauge/Gage Inaccurately Reads Empty, Low Fuel Light On (Diagnose and Repair Using SI) Models: 2008-2009 Buick Lucerne 2008-2009 Chevrolet Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 08-08-49-016B (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. This bulletin is being revised to end the need for dealer feedback. If you encounter a vehicle with this concern, please diagnose and repair using the information found in SI. Disclaimer Page 18453 For vehicles repaired under warranty, use the table. Disclaimer Page 8084 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 2511 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the fill plug (1). 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Diagrams Power Distribution Module: Diagrams Component Connector End Views Accessory DC Power Control Module X1 (HP2) Accessory DC Power Control Module X2 (HP2) Page 14201 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 8934 17. Disconnect the range selector lever cable (2) from the range select lever. 18. Remove the range selector lever cable retainer (1). 19. Remove the range selector lever cable (2) from the cable bracket. Installation Procedure 1. Install the transmission range selector cable to the vehicle. 2. Ensure that the transmission manual shaft lever is in the mechanical park position. 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. Page 9111 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Torque Converter Clutch (TCC) Solenoid Valve (M30) Page 15022 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 8862 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 3895 Intake Manifold: Service and Repair Intake Manifold Cover Replacement Intake Manifold Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Perform the High Voltage Service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 4. Remove the engine harness retainer nut (1). 5. Remove the engine harness retainer from the stud and locator pin. 6. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid. 7. Disconnect the engine wiring harness electrical connector (3) from the manifold absolute pressure (MAP) sensor. Page 14485 1. Install the lower ball joint in the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement )Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement) . 2. Install upper ball joint in the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement) . 3. Install the outer tie rod end in the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 4. Install the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Wheel Hub/Service and Repair) . 5. Install the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 7. Remove the support and lower the vehicle. 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications) . A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 4055 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 1092 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 7643 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 2985 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 2364 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 20508 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9845 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 19322 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair) . 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. Page 15133 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement Sealing Washer Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Page 10249 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 5682 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 2260 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4 - 310.3 kPa (43 - 45 psi). Circuit/System Testing Important: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from theCH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with theCH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer toSymptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (2500/3500 Regular Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Crew Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Regular Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Extended Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Locations Impact Sensor: Locations Door Component Views Right Rear Door Components (Extended Cab) 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Locations Battery, Hybrid Drive: Locations Hybrid Controls Electronic Component Views High Voltage Ring Terminal Locator 1 - Air Conditioner Compressor 300 V B- 2 - Air Conditioner Compressor 300 V B+ 3 - Motor 2 Phase U 4 - Motor 2 Phase W 5 - Motor 2 Phase V 6 - Motor 1 Phase U 7 - Motor 1 Phase W 8 Motor 1 Phase V 9 - Drive Motor Generator Battery 300 V B- 10 - Drive Motor Generator Battery 300 V B+ Page 6928 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Page 14980 Blower Motor Control Module X2 Page 7393 26 - Front Differential Case 27 - Differential Pinion Gear Shaft Lock Bolt 28 - Differential Side Bearing 29 - Differential Side Bearing Cup 30 - Front Differential Ring Gear 31 - Front Differential Half Carrier Location Pin 32 - Front Differential Bearing Adjuster Nut Lock 33 - Differential Pinion Gear 34 - Differential Pinion Gear Thrust Washer 35 - Differential Side Gear Thrust Washer 36 Differential Side Gear 37 - Differential Pinion Gear 38 - Differential Pinion Gear Thrust Washer 39 Front Differential Side Gear Spacer 40 - Front Differential Side Gear 41 - Front Differential Side Gear Thrust Washer 42 - Front Differential Drive Pinion Gear 43 - Differential Drive Pinion Gear Bearing Shim 44 - Front Differential Drive Pinion Gear Inner Bearing 45 - Front Differential Drive Pinion Gear Inner Bearing Cup 46 - Front Differential Drive Pinion Gear Bearing Spacer 47 - Front Differential Carrier Bushing 48 - Front Differential Carrier 49 - Front Differential Bearing Adjuster Nut Lock 50 - Bolt 51 - Front Differential Drive Pinion Gear Yoke Nut 52 - Front Differential Drive Pinion Gear Thrust Washer 53 - Front Differential Drive Pinion Gear Yoke 54 - Front Differential Drive Pinion Gear Bearing Dirt Deflector 55 - Front Differential Drive Pinion Gear Seal 56 - Front Differential Drive Pinion Gear Outer Bearing Cup 57 - Front Differential Drive Pinion Gear Outer Bearing 58 - Front Differential Carrier Bushing 59 - Differential Bearing 60 - Front Differential Bearing Adjuster O-Ring Seal 61 - Front Differential Bearing Adjuster 62 - Front Drive Axle Inner Shaft Seal 63 - Front Drive Axle Inner Shaft Retaining Ring 64 - Front Drive Axle Inner Shaft 65 Front Differential Carrier Vent 66 - Fuel and Oil Resistant Hose 67 - Clamp 68 - Front Differential Carrier Vent Hose Connector 69 - Front Differential Carrier Oil Drain Plug 70 - Front Differential Carrier Oil Drain Plug Washer 71 - Front Differential Carrier Oil Fill Plug 72 - Front Differential Carrier Oil Fill Plug Washer Page 17351 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab Lower) Door Striker Replacement (Extended Cab Lower) Removal Procedure Note If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the door lower striker bolts (1). 2. Remove the spacer, if equipped. 3. Remove the door lower striker (2). Installation Procedure Page 12429 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 793 Page 12126 Junction Block - Right I/P X4 Page 2875 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 10251 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 6143 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 18868 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics Heated Seat - Driver (AN3 without KB6) Heated Seat - Passenger (AN3 without KB6) Page 8637 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 5203 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Page 20909 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 13396 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 249 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 12030 Page 19824 Fuel Pump and Sender Assembly - Front (MEX) Page 10446 A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 4793 Body Control Module (BCM) X3 Component Locations Power Window Switch: Component Locations Door Component Views Left Rear Door Components (Extended Cab) 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Page 4638 9. Remove the caps (3, 6) from the drive motor generator power inverter coolant pipes. 10. Connect the drive motor generator power inverter module (PIM) cooling inlet and outlet hoses (4, 5). 11. Install the shield circuit harness (1) and terminal fastener (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 12. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6). 13. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 14. Install the PIM 3 phase cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . Page 18777 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2353 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 11850 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 13785 X350 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) Page 3011 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 13819 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 3550 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 11356 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Specifications Spark Plug: Specifications Ignition System Specifications Locations Garage Door Opener Transmitter: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 18412 For vehicles repaired under warranty, use the table above. Disclaimer Page 9019 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 9101 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 16950 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 4998 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 6950 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 8872 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 8873 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 17055 Page 14726 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 1050 Transfer Case Shift Control Module X3 (NQF/NQH) Page 5498 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 7175 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 11667 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 14953 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) Page 4510 20. Install a new seal (3) on the PIM distribution box. 21. Position the terminal cover (2) onto the PIM distribution box ensuring the seal remains in place. 22. Tighten the terminal cover fasteners (1). Tighten the fasteners to 9 Nm (80 lb in). 23. Perform the high voltage enabling. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 7719 Page 7370 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 8274 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 3438 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Replacement Camshaft Position Actuator Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . 2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234). Page 4221 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 5731 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 2784 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 10719 Page 13751 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (HP2/Late Production except Y91/MEX/8S8) Page 10415 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 14879 Air Door Actuator / Motor: Service and Repair HVAC - Automatic Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Page 12424 Fuse Block - Auxiliary X3 (HP2) Page 4551 Drive Motor Control Module: Service and Repair Accessory DC Power Control Module Removal and Installation Accessory DC Power Control Module Removal and Installation Special Tools * J 24460-01 - Cooling System Pressure Tester * GE-48494 - Power Electronics Pressure Test Adapter Kit Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the APM ground strap bolt (1) and ground strap (2). Page 5962 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 8831 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 15461 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Page 12624 X176 Engine Harness to Transmission Harness (M99) Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 13037 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 16521 Page 19131 11. Reinstall the foam (1) to the latch rod. 12. Reinstall the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 13. Reinstall the right endgate latch. Refer to Endgate Latch Replacement in SI. 14. Reinstall the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10435 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 6135 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 509 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 1507 Generator Battery Vent Fan Relay (HP2) Page 6081 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 9465 9. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 10. Install the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note If the wheel hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the wheel hub seal must be replaced. 12. Install the wheel hub to the axle housing. 13. Using the J 2222-C - wrench , install the adjusting nut to the hub. 14. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) . 15. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 16. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 17. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 18. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . 19. Lower the vehicle. Page 18997 Seat Recline Position Sensor - Driver (AN3) Page 9 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 10513 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 10399 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8286 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 4201 Page 10220 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 1880 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 5257 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 20957 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 20660 Window Switch - Passenger (A31 without AN3/DL3) Page 13002 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 11120 13. Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination. 14. Release the supply and return hoses from the retainers and remove the hoses from the vehicle. Installation Procedure 1. Install the supply and return hoses to the vehicle and the retainers. 2. Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting. Page 19069 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Page 1509 Generator Control Module Temperature Sensor (HP2) Page 6503 4. Remove the PCV fresh air tube (1) from the right valve rocker arm cover fitting (2), if required. 5. Remove the appropriate PCV hose/tube from the vehicle. Installation Procedure 1. Install the appropriate PCV hose/tube to the vehicle. 2. Install the PCV fresh air tube (1) to the right valve rocker arm cover fitting (2), if required. Page 320 Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 12972 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 6738 19. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 20. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 21. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 22. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 23. Remove the EVAP tube and purge solenoid. Page 16645 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Page 7238 Page 13699 1 - Door Frame 2 - X700 Right Rear Door Harness Routing (Extended Cab) MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Page 4518 Drive Motor Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 545 Page 12936 Page 5829 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 10008 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 16639 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 13187 Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 12615 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 7737 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 10472 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 13363 Junction Block - Right I/P X3 Page 19579 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19059 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair) . 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair) . Page 11457 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 8216 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12821 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 19462 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6915 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 6969 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Page 13558 Junction Block - Left I/P X9 (except MEX) Page 1635 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 1076 Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt - First Pass................................................................................................... .......................................................150 Nm (110 lb ft) Crankshaft Balancer Bolt - Second Pass......... ......................................................................................................................................Loosen 360 degrees Crankshaft Balancer Bolt - Third Pass................................................................................... .........................................................................50 Nm (37 lb ft) Crankshaft Balancer Bolt - Final Pas s............................................................................................................................................................ ........230 degrees Page 8848 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 10276 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 13674 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6400 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12470 Fuse Block - Underhood X1 Page 16701 Speaker: Diagrams Component Connector End Views Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Page 9002 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14753 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 19247 Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 6791 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Page 20448 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 10184 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 14816 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 13539 Fuse Block - Auxiliary X2 (HP2) Page 17148 Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 17672 Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Right Side Front Wheelhouse Liner Replacement - Right Side (Chevrolet) Page 9210 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 9873 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. Page 5930 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Service and Repair Drink Holders: Service and Repair Front Floor Console Cup Holder Replacement Page 6281 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. If equipped with 2 wheel drive (2WD) perform the following steps, if equipped with 4 wheel drive (4WD) proceed to step 5. 3. Remove the connector position assurance (CPA) retainer (2). 4. Disconnect the HO2S electrical connector (3) from the engine wiring harness electrical connector (5). 5. Remove the connector position assurance (CPA) retainer (2). 6. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Page 9253 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Page 4711 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Page 1183 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in) . 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 11333 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the HPA (1) to the brake modulator assembly and tighten to 30 Nm (22 lb ft) . 4. Install the brake modulator assembly bracket and remove the support. Refer to Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) . 5. Tighten the brake modulator manual pressure relief valve (1) to 40 Nm (30 lb ft) . 6. Perform theAntilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair) . Follow the procedure completely to ensure the learn procedure for the pressure and travel sensors has occurred. Page 20208 Diagrams Positive: Diagrams Component Connector End Views Battery - Left (+) (Auxiliary Battery Positive Cable) (TP2) Battery - Left (+) (Starter Cable) (6A6/Diesel) Battery - Right (+) (Diesel/9L4) Battery - Right (+) (Gas without 9L4) Battery (+) (Battery Positive Cable) (HP2) Page 15544 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 Page 20191 Page 13467 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2627 Fuse: Locations Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 19573 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 17133 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 2270 4. Tighten the air cleaner outlet duct clamp (1) at the MAF/IAT sensor. Tighten the clamps to 4 Nm (35 lb in). 5. Install the radiator inlet hose clamp clip (2) to the air cleaner outlet duct (1). 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 8058 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 15556 Page 11846 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 7498 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 7082 4. Brush or using compressed air, blow away any dirt from around the spark plug. 5. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Page 13771 Page 6911 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 5760 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Page 11779 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Page 8260 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 12766 X700 Body Harness to Left Rear Door Harness (Crew Cab) Page 1002 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 11100 19. Install the ABS module splash shield (1). 20. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . Page 414 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Locations Brake Light Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 17420 Disclaimer A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11659 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 19458 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 6769 21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft). 22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 23. Lower the vehicle. 24. Remove the caps from the fuel rail and EVAP line. 25. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 26. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 27. Install the fuel fill cap. 28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Page 413 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 20522 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 4342 Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Hanger Mounting Bracket Replacement Removal Procedure 1. If equipped with a 6.0L engine, remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement) . 2. If equipped with a 6.0L engine, remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (With Cab Chassis) ( See: Catalytic Converter/Service and Repair) . 3. If equipped with a 6.6L engine, remove the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . 4. If equipped with a 4L80-E automatic transmission, regular production option (RPO) MT1, remove the exhaust pipe hanger bracket bolts and bracket. Page 6633 Fuel Injector: Diagrams Component Connector End Views Fuel Injector 1 (4.3L) Fuel Injector 1 (4.8L/5.3L/6.0L/6.2L) Page 5152 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 7. Remove the HO2S (4). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 11815 Component Parts Page 3620 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Tune-up and Engine Performance Checks/Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Page 12954 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics) . Page 11636 Component Parts Page 12015 Fuse Block - Auxiliary (HP2), Bottom View Page 13511 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 20932 Windshield Washer Pump: Diagrams Component Connector End Views Windshield Washer Fluid Pump Page 7661 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 12324 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 11682 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2230 Alignment: Specifications Trim Height Specifications Trim Height Specifications Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 93 Page 257 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1359 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 20754 Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Extender Cab) Rear Side Door Window Replacement (Extender Cab) Page 5696 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 20865 Locations Coolant Level Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Page 6379 3. Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid. 4. Connect the chassis EVAP line quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Connect the EVAP line quick connect fitting to the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 6. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 5235 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 13058 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 13720 X110 Inline Harness Connector End Views X110 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH) Page 20715 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2647 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 1747 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Page 14948 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 12648 Multiple Junction Connector: Diagrams X300 - X399 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) X300 Chassis Harness to Engine Harness (4.3L) Page 6072 Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Page 17569 Note Use a suitable tool to release the tabs (1) from the rear sliding window pulley (3). 4. Remove the rear sliding window pulley covers (2). 5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame. Page 7806 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 5520 Data Link Resistor 2 (HP2) Page 4001 1. If replacing the front cover perform the following steps, otherwise proceed to step 10. 2. Install a NEW CMP actuator magnet gasket (753) onto the magnet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the CMP actuator magnet (752) and bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Inspect the CMP sensor O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be reused. 5. Lubricate the O-ring seal (704) with clean engine oil. 6. Install the CMP sensor (703). Page 20138 Page 19386 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 19597 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13981 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14031 2. Obtain a revised wiring harness clip (Warranty Parts Center (WPC) # 577) from the WPC. Refer to Parts Information below. 3. Insert the motor harness (minus the two separate brown wires) into the revised wiring harness clip. 4. Position the two brown wires into the access slot (1) located on the internal side of the wiring harness clip. 5. Engage the locking tab (1) to retain the harness within the clip. 6. Install the wiring harness clip back into the motor housing. The drive motor is now ready to be installed into the transmission case. Parts Information To obtain the revised wiring harness clip, fax the form included in this bulletin to the GM Warranty Parts Center (WPC). Request WPC#577 for the wiring harness clip. Page 11784 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 8158 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 14515 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 19413 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 7795 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13304 Page 8605 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18805 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 1788 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 6340 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Restraints - Seat Belt Latch Stop Button Availability Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9424 Note Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the NEW ring gear bolts and tighten to 120 Nm (89 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement) . 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle) )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 8. Remove the support and lower the vehicle. Page 13484 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 10335 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 13004 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 8780 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 13986 2. Obtain a revised wiring harness clip (Warranty Parts Center (WPC) # 577) from the WPC. Refer to Parts Information below. 3. Insert the motor harness (minus the two separate brown wires) into the revised wiring harness clip. 4. Position the two brown wires into the access slot (1) located on the internal side of the wiring harness clip. 5. Engage the locking tab (1) to retain the harness within the clip. 6. Install the wiring harness clip back into the motor housing. The drive motor is now ready to be installed into the transmission case. Parts Information To obtain the revised wiring harness clip, fax the form included in this bulletin to the GM Warranty Parts Center (WPC). Request WPC#577 for the wiring harness clip. Page 2508 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities andAdhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft) . 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Page 16253 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 12675 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Page 7351 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 20439 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 2942 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 13612 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Page 10866 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16497 Disclaimer Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 17940 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Page 19028 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 Page 5547 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 3765 Disclaimer Page 13705 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Page 18798 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 9026 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7129 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 15163 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13861 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (Except MEX) Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 12725 X214 Inline Harness Connector End Views Page 6916 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 874 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in) . 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in) . 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 7139 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 12537 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 19056 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Body - Roof Panel Flutters/Rattle Noise When Doors Close Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 18771 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 11258 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 18829 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12396 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 8312 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 13656 For vehicles repaired under warranty, use the table. Disclaimer Page 11476 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 5469 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10732 Note To ensure brake modulator and HPA pressure relief has occurred, the manual pressure relief valve must be opened momentarily. 7. Loosen the brake modulator manual pressure relief valve (1) 1/4 turn counterclockwise. 8. Seat, but do not tighten, the manual pressure relief valve. 9. Disconnect the electronic brake control module (EBCM) electrical connector. 10. Disconnect the electronic brake control position sensor electrical connector. 11. Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination. Page 18849 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 6636 Fuel Injector 2 (Diesel) Page 6713 * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 . 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Remove the J 37287 andCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal ). 5. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system components test normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Service and Repair )Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair) Fuel System Diagnosis (W/FPCM) Page 13388 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 8238 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3785 Tighten the bolts/nuts to 100 Nm (74 lb ft). 10. If equipped, install the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 11. Remove the jack or utility stand from the rear of the vehicle. 12. Lower the vehicle. Note * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 13. If equipped with RPO LY6 (6.0L) engine, install the oil cooler hoses to the clip. Note Page 9694 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 10193 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 1315 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 12976 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 11662 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 4718 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 4824 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 3465 Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 9. Install the camshaft sprocket bolt into the camshaft front bolt hole. 10. Using the bolt as a handle, carefully rotate and remove the camshaft from the engine block. 11. Remove the bolt from the camshaft. Installation Procedure 1. Lubricate the camshaft journals and the bearings with clean engine oil. 2. Install the camshaft sprocket bolt into the camshaft front bolt hole. Caution: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolt as a handle, carefully install the camshaft into the engine block. Page 1822 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 11519 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 6173 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 5671 Page 8014 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 9391 Note Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 7. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup from the axle housing. Note Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 8. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup from the axle housing. Assemble Procedure Page 12746 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 1833 Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (1). Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 5582 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 2853 Junction Block - Right I/P X3 Page 3378 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Page 5578 Page 9061 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8209 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 9572 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Page 2906 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 847 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 - X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) Page 13179 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 5714 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 20883 use of any similar HWFS products that may be sold by aftermarket suppliers. Even though you have declined to have this safety recall performed on your vehicle, please be advised that if you change your mind, your GM dealer will always be available to remove the HWFS from your vehicle and provide reimbursement according to the terms described in the recall notification letter. As part of this declination process, your dealer will ask you to document your refusal to have Safety Recall 10153 performed on your vehicle by signing a Repair Order stating "customer declined recall repair". You will be given a copy of this document for your records. Of course, your signature is voluntary but doing so will help prevent the mailing of recall reminder notices to you as the current owner of record. If you sell this vehicle, you should advise the buyer that this safety recall was not performed on the vehicle and that the recall repair is still available. This notice should also be placed in the glove box so that a future owner of this vehicle will be aware of this safety recall. Page 7837 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 17656 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 15977 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Page 10428 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 13693 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 13073 Auxiliary Power Outlet: Tools and Equipment Special Tools Page 1470 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 12134 Junction Block - Rear Lamps X3 Page 11394 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 11464 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Page 4682 9. Remove the caps (3, 6) from the drive motor generator power inverter coolant pipes. 10. Connect the drive motor generator power inverter module (PIM) cooling inlet and outlet hoses (4, 5). 11. Install the shield circuit harness (1) and terminal fastener (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 12. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6). 13. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 14. Install the PIM 3 phase cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . Engine Controls - Cruise Control Turns Off When Operated Cruise Control: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11689 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6563 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Page 15096 Control Module HVAC: Diagrams HVAC Control Module Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67/C42/MEX) Page 4829 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 7879 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Locations Steering Control Module: Locations Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 20222 Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 18738 Page 13391 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 17829 Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Page 2841 Junction Block - Left I/P X8 (except MEX) Page 13532 Page 13126 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 15751 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Crew Cab) Seat Belt Replacement - Center Rear (Crew Cab) Page 12279 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 12427 Page 9809 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 12695 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (4.8L/5.3L/6.0L/6.2L) Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Oil Pan Cover Replacement Oil Pan: Service and Repair Oil Pan Cover Replacement Oil Pan Cover Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the oil pan cover bolts (435), cover (434), and gasket (433). Discard the gasket. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position a NEW oil pan cover gasket (433) and the cover (434) to the oil pan and install the bolts (435). Tighten the bolts to 12 Nm (106 lb in) . 2. Lower the vehicle. Page 12112 Junction Block - Left I/P X8 (except MEX) Page 5004 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Page 2105 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 7092 Pressure Regulating Solenoid: Service and Repair Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the range selector lever cable heat shield bolts (1). 3. Remove the range selector lever cable heat shield (2). 4. Disconnect the range selector lever cable (2) from the range select lever. 5. Remove the range selector lever cable retainer (1). 6. Remove the range selector lever cable (2) from the cable bracket. Page 8247 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 2649 Page 10364 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 13094 Warranty Information (Saab U.S. Models) Disclaimer Locations Canister Purge Solenoid: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 11274 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling) . 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Remove the park brake cable from the cable guides. 9. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair) . Page 2144 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 6513 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 9010 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 20594 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 10757 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 17307 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 12455 Junction Block - Right I/P X4 Page 9432 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement) . 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft) . 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 16. Lower the vehicle. Page 15565 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 11941 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 5611 Page 5771 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18633 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 12688 Page 17084 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34/KA9) Steering Wheel Control Switch - Right (UK3) Page 15414 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 5408 Body Control Module (BCM) X3 Page 7000 18. Perform the service reconnect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Diagrams Barometric Pressure Sensor: Diagrams Component Connector End Views Barometric Pressure (BARO) Sensor (HP2) Page 17777 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 4792 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Body Control Module (BCM) X2 Page 8453 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 10933 Brake Rotor/Disc: Specifications Front Brakes JD9, JF3, JF7 Rotor Discard Thickness*........................................................................ ....................................................................................................28.0 mm (1.10 in) Rotor Minimum Allowable Thickness After Refinish..................................................................................................................................28.0 mm (1.10 in) Rotor Thickness (new)........................................................................................................... ....................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Front Brakes JH6, JH7 Rotor Discard Thickness*........................................................ ................................................................................................................36.50 mm (1.437 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................37.0 mm (1.457 in) Rotor Thickness (new)......................................................................................................... ......................................................................38.0 mm (1.496 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JD9 Rotor Discard Thickness*................................................................. .........................................................................................................18.0 mm (0.709 in) Rotor Minimum Allowable Thickness After Refinish..............................................................................................................................18.5 mm (0.7282 in) Rotor Thickness (new)....................................................................................................... ........................................................................20.0 mm (0.787 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation...................................................................................................................................0.009 mm (0.0004 in) Rear Brakes JH6 Rotor Discard Thickness*............................................................... ...........................................................................................................27.5 mm (1.083 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................28.0 mm (1.102 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JH7 Rotor Discard Thickness*................................................................. .........................................................................................................28.5 mm (1.122 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................29.0 mm (1.142 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Page 5593 Engine Control Module (ECM) X1 (Gas Except 4.3L/LY6/HP2) Diagrams Auxiliary Water Pump: Diagrams Component Connector End Views Heater Coolant Pump (HP2) Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3943 Remove the spark plugs from the cylinder head with the engine at room temperature. 3. Loosen the spark plug 1 or 2 turns. 4. Brush or air blast away any dirt or debris from around the spark plug. 5. Remove the spark plug. 6. Install the J 22794 into the spark plug hole. 7. Attach an air hose to the J 22794 . 8. Apply compressed air to the J 22794 in order to hold the valves in place. 9. Use the J 38606 in order to compress the valve spring. 10. Remove the valve stem keys (225). Page 20200 Page 12756 X350 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) Page 15065 Page 14940 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) Page 2919 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2915 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4473 Drive Motor Generator Battery Control Module X5 (HP2) Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Special Tools * J 29532 Diaphragm Pressure Bleeder, orJ-29532-A Brake Pressure Bleeder, or equivalent * J 35589-A Brake Bleeder Adapter, or equivalent Warning At times during this brake bleed procedure brake fluid will be under higher pressures than during typical brake bleed procedures. Ensure the bleeder hose attached to the bleeder valve is securely maintained in position whenever the bleeder valve is opened. Failure to maintain the bleeder hose securely to the valve when opened, may allow the hose to blow off and brake fluid to spray out of the bleeder valve, possibly resulting in personal injury. Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note * Do not pressurize the brake pressure bleederJ-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. Portions of the automated bleed process require the master cylinder reservoir not be pressurized through the J-29532-A orJ 29532 . * Do not apply the brake pedal until instructed to do so by the scan tool. Applying the brake pedal before instructed by the scan tool may result in setting a DTC and may require the sensor and boost valve calibration and electronic brake control module (EBCM) learn procedures to be repeated manually. 1. Place the transmission in the PARK or NEUTRAL position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 2. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 5. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as necessary. 6. Lower the vehicle to allow for entry and exit while bleeding the brake corners and other components. 7. Connect a battery charger to the 12V battery. The battery charger must remain connected for the entire automated bleed procedure. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) . 8. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during the entire automated bleed procedure. 9. Turn the ignition switch to the ON position with the engine OFF. Note Do not pressurize the pressure bleederJ-29532-A orJ 29532 , and thereby the master cylinder reservoir, until instructed to do so by the scan tool. 10. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions Page 240 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 18599 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 10734 15. Disconnect the primary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 16. Disconnect the right supply brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 17. Disconnect the left supply brake pipe fitting (2). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 16753 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 12605 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (4.8L, 5.3L, 6.0L and 6.2L) Page 20520 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 4709 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Drive Motor Generator Power Inverter Module X5 (HP2) Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 18055 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 8593 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 7305 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 12205 Page 20187 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 7384 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Torque Converter Clutch (TCC) Solenoid Valve (M30) Diagrams Barometric Pressure Sensor: Diagrams Component Connector End Views Barometric Pressure (BARO) Sensor (HP2) Page 3031 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 19676 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 20786 Note When installing the regulator (2) align the gear to the motor drivegear before installing the screw. 3. Install the regulator (2) to the motor/module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the screw (1) to the motor/module. Tighten nuts to 5 Nm (44 lb in). Note When removing the tension from the cables, depress and hold spring on the regulator to remove tension from the cable before locking the pulley into the frame. Once the pulley has been locked, the spring can then be release. 5. Install the rear sliding window pulley (1). Page 6300 Page 10405 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 1972 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (Except 10 Series) Page 11891 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7769 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12538 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 8718 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 13148 Fuse Block - Underhood Bottom View Page 8011 24 - Transfer Case Oil Fill Plug 25 - Transfer Case Oil Drain Plug 26 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 27 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 28 - Transfer Case Shift Detent Plunger Plug 29 - Transfer Case Shift Detent Plunger Plug - O-Ring - Seal 30 - Transfer Case Shift Detent Spring 31 - Transfer Case Shift Detent Plunger Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 - Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Insert 12 - Transfer Case Shift Fork Spring Page 17062 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement (Gas) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) ()Refrigerant Recovery and Recharging (HP2) () . 2. Remove the fascia. 3. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to Radiator Support Replacement () . 4. Remove radiator support bracket bolts (1). 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. Page 6743 17. Position and install the heater hose bracket (1) to the ignition coil bracket stud. Hoses shown removed for clarity. 18. Install the heater hose bracket nut (2). Tighten the nut to 9 Nm (80 lb in). 19. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 20. Install the CPA retainer. 21. Connect the engine wiring harness electrical connector (2) to the electronic throttle control. 22. Connect the engine wiring harness electrical connectors (5) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 23. Install the engine wiring harness clip (4) to the ignition coil bracket stud. Page 9232 8. Remove the control valve body bolts (1). 9. Remove the automatic transmission shift shaft position switch bracket (2). 10. Remove the control valve channel plate bolts (1). Page 3353 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 15421 Page 10677 Page 15057 Page 15017 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 10301 Page 3070 MP 1222/1225/1226-NQG - Transfer Case Transfer Case Actuator: Locations MP 1222/1225/1226-NQG - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 16789 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 12771 Page 7755 View of the connector when released from the component. View of another type of Micro 64 connector. Page 11080 Page 18605 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 5672 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 11349 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 8787 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 19466 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 12941 Page 12990 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 20825 Page 12496 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Page 6647 Central Sequential Fuel Injection (Central SFI) X1-X6 (4.3L) Central Sequential Fuel Injection (Central SFI) X7 (4.3L) Page 10202 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 16812 Page 2330 Drive Belt: Service and Repair Drive Belt Replacement - Accessory Drive Belt Replacement - Accessory Removal Procedure 1. Open the hood. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 3. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 4. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 5. Remove the drive belt (1) from the pulleys and the drive belt tensioner. 6. Slowly release the tension on the drive belt tensioner. 7. Remove the breaker bar and socket and from the drive belt tensioner bolt. 8. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 9. Start the vehicle and inspect the drive belt for proper operation. 10. Close the hood. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 18905 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 7833 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 8178 Page 3858 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 14874 Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Air Temperature Actuator (C67/C42) Page 11848 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 7786 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 18584 Page 13450 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 10060 Transfer Case Shift Control Module X3 (NQF/NQH) Page 9816 Transfer Case Shift Control Module X3 (NQF/NQH) Page 7834 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 10747 21. Install the ABS module splash shield retainer (1). 22. If installing a new EBCM, the EBCM must be programmed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . 23. Perform theAntilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair) . Follow the procedure completely to ensure the sensor and boost valve calibration and EBCM learn processes have been completed. Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5778 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 1632 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 8258 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 6368 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11829 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 13564 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Page 11491 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 5137 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (6.0L with ZW9) Page 5006 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Page 11468 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 2910 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9863 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 13016 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 16199 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 6285 Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (1). Page 6357 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 8273 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 19992 Courtesy Lamp: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Sliding Rear Window Jumper Harness Routing (A48) Page 12175 Fuse Block - Auxiliary X2 (HP2) Page 10354 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 3109 Page 19319 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 12141 Page 4422 Drive Motor Generator Battery Control Module X3 (HP2) Page 11922 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 6269 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 13866 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Center Console End Panel Replacement Console: Service and Repair Center Console End Panel Replacement Center Console End Panel Replacement Page 20838 Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 5516 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 18875 Seat Heater: Description and Operation Heated/Cooled Seats Description and Operation Heated/Cooled Seats Description and Operation The driver and front passenger heated cooled seat system consist of the following components: * Heated and cooled seat switch * Door lock/window switch * Memory seat module * Driver and passenger seat back heat/cool ventilation blowers * Driver and passenger seat cushion heat/cool ventilation blowers Heated/Cooled Seat Switches The heated and cooled seat system is controlled through the heated and cooled seat switches that are located on the door panels. When either the heat or cool seat switch is pressed, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial data message to the memory seat module (MSM) indicating the switch input. In response to this message, the MSM then sends a pulse width modulation (PWM) signal through the heated/cool seat mode signal circuit to the CCSM indicating the heated or cooled seat request. The door lock/window switch then applies a ground through the appropriate heat or cool seat indicator control circuit to the switch illuminating the selected heat or cool mode indicator. At the same time, the door lock/window switch also applies a ground through the appropriate high, medium, or low temperature indicator control circuits illuminating temperature mode indicators. Memory Seat Module The memory seat module monitors the heated cooled seat switches through GMLAN message inputs and determines the heated cooled seat operating modes and temperature levels. When heated or cooled seat switch active signals are received through GMLAN messages, and vehicle conditions are appropriate to allow heated or cooled seat operation, the memory seat module (MSM) will calculate the switch activations and determine the heated or cooled seat operating modes. The MSM controls the operating mode of the Climate Control Seat Module (CCSM) through 2 pulse width modulation (PWM) signal circuits. The left and right heated/cooled seat mode signal circuits are referenced from battery voltage by the CCSM and pulsed low by the MSM. Each heated cooled seat is capable of operating in 3 modes with 3 temperature levels so the MSM uses 9 PWM frequencies for each signal circuit to command the heated cooled seat modes to the CCSM. Climate Control Seat Module The Climate Control Seat Module (CCSM) is located under the passenger seat and controls 4 individual driver and passenger seat heat/cool ventilation blowers. When the CCSM receives a heated cooled seat command through the left or right heated/cooled seat mode signal circuit, the appropriate seat heat/cool ventilation blowers will be operated by the CCSM. Seat Heat/Cool Ventilation Blowers The ventilation blowers are self contained electronic air conditioners consisting of a blower motor with an inlet air filter, thermal electric device (TED), temperature sensor, and waste air duct. The air flow from the blower is divided into 2 streams and directed across both sides of the TED, one side into vent passages through the seat foam and the other out the waste air duct. While the system is operating in either the heat or cool modes both heated and cooled air is generated as it passes across the TED. When voltage is applied to a TED, one side releases energy as heat, while the opposite side absorbs energy and gets cold. Heat or cool modes are determined by the polarity of the supply voltage to the TEDs. The climate control seat modules (CCSM) rely on inputs from temperature sensors located in the ventilation blowers near the TEDs to control seat temperatures. The thermistors are 2 wire sensors supplied with a 5 V referenced signal circuit and a low reference circuit from the CCSM. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the TED temperatures rise. The CCSM monitors the temperature of the air flow into the seat foam and continuously adjusts the blower speed and TED temperature by regulating the current flow through each component. Page 10231 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12712 X176 Engine Harness to Transmission Harness (M99) X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Page 16454 Garage Door Opener Transmitter: Diagrams Component Connector End Views Garage Door Opener (UG1) Page 4716 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 15709 Page 988 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 7208 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 1552 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 1806 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 6651 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel Pressure Test for further diagnosis of the fuel injectors. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Fuel Injector Balance Test-Fuel Pressure Test 1. Install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure/Testing and Inspection/Fuel Pressure Gage Installation and Removal) . 2. Turn ON the ignition, with the engine OFF. Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 3. Command the fuel pump relay ON with a scan tool. 4. Observe the fuel pressure gage with the fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi). ‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer toFuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 5. Monitor theCH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa (5 psi). ‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer toFuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 6. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with Tech 2. Fuel Injector Balance Test with Special Tool 1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amp position. 2. Connect the J 39021 to a fuel injector with aJ 44602 . 3. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing the Push to Start Test button on the J 39021 at the previously selected pressure. 5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. Page 18497 Seat Adjuster Motor Assembly - Driver X2 (AN3) Page 19349 Module Circuit Function Icons Page 13125 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 13966 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2521 Note Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Transfer Case/Specifications/Fluid Type Specifications) . 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 6. Lower the vehicle. Page 9920 Transfer Case Actuator: Locations MP 1625/1626-NQF - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 - Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor - O-Ring - Seal 15 - Transfer Case Rear Half 16 Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 22 - Transfer Case Two/Four Wheel Drive Actuator Assembly 23 - Transfer Case Two/Four Wheel Drive Actuator Seal Page 7451 Director, Customer and Relationship Services 09241 Page 12967 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 6966 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 11942 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 4649 board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 7. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. 8. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 9. Rotate the drive motor generator control module assembly onto the PIM cover. 10. Remove the APM to PIM mounting fasteners (1). 11. Remove the APM (2) and discard the coolant seal (3). Installation Procedure Page 12061 Fuse Block - Auxiliary X2 (HP2) Page 19559 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6612 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Page 6314 camshaft lobe, the valve spring force is reduced, allowing the locking pins to move, deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve lifter to move immediately, and deactivate the exhaust valve. By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge or exhaust gas charge in the combustion chamber. The capture of exhaust gases in the combustion chamber will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions when operating in V4 mode cylinder deactivation mode. During the transition from V8 to V4 mode, the fuel injectors will be turned OFF on the deactivated cylinders. To help prevent spark plug fouling, the ignition system secondary voltage or spark is still present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder deactivation to a cycle time of 10 minutes in V4 mode, then return to V8 mode for 1 minute. Switching between V8 and V4 modes is accomplished in less than 250 milliseconds, making the transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the time for the ECM to sequence the transitions, the response time for the VLOM solenoids to energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine crankshaft. Valve Lifter Oil Manifold (VLOM) Assembly The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake manifold assembly. The VLOM consists of 4 electrically operated normally closed solenoids. Each solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from an internal oil passage on the rear of the cylinder block. All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the powertrain relay. The ground or control circuit for each solenoid is connected to a low side driver internal to the engine control module (ECM). When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid control circuit in firing order sequence, allowing current to flow through the solenoid windings. With the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When vehicle operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil pressure in the control ports is exhausted through the body of the solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds in the oil passages to purge any air trapped in the VLOM or engine block. To help control contamination to the hydraulic circuits, a small replaceable oil screen is located in the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire sensor which provides oil pressure information to the ECM. During service, use extreme care in keeping the VLOM assembly free of any contamination or foreign material. Cylinder deactivation may be inhibited for many reasons, including the following: * Engine coolant temperature out of range for cylinder activation * Engine vacuum out of range * Brake booster vacuum out of range * Transmission gear incorrect or shift in progress * Accelerator pedal out of range or rate of pedal application too fast * Engine oil pressure and temperature out of range * Engine speed out of range * Vehicle speed out of range * Minimum time in V8 mode not met * Maximum V4 mode time exceeded * Decel fuel cutoff active * Reduced engine power active * Torque management active * Catalytic converter over temperature protection active * Piston protection active, knock detected * Cylinder deactivation solenoid driver circuit faults Page 4695 10. Remove the PIM cover retaining bolts (1). 11. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 12. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 3835 3. Ensure that the oil pan drain plug is tight. Tighten the drain plug to 25 Nm (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities . 6. Start the engine and inspect for leaks. Page 14240 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 13322 Fuse Block - Underhood X4 Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 17511 Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement Rear Side Door Water Deflector Replacement Page 1131 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 15115 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 19831 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 12233 Junction Block - Left I/P X5 (SPO Alarm) Page 20949 9. Install the left front wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 10. Fill the washer solvent container with windshield solvent. Refer to Fluid and Lubricant Recommendations . 11. Install the windshield washer solvent cap. Page 15164 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair) . 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. 3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal. 4. If equipped remove the screws from the HVAC module assembly. 5. Remove the evaporator cowl gasket from the evaporator. 6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1) Page 11721 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 16465 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 20876 dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Windshield Washer Solvent Heater Removal WINDSHIELD WASHER SOLVENT HEATER REMOVAL 1. Disconnect the windshield wiper solvent inlet and outlet hoses (1) from the windshield washer solvent heater assembly and from the two plastic inlet and outlet windshield wiper solvent hoses. Note Do NOT remove the connector retention clips from the connectors. Do NOT remove the assembly bracket from the engine compartment. 2. Disconnect the two electrical connectors at the windshield washer solvent heater assembly. 3. Remove the windshield washer solvent heater assembly from the assembly bracket using a small flat blade screwdriver. 4. Place the windshield washer solvent heater assembly on a work bench. 5. Cut the two-wire connector from the windshield washer solvent heater assembly. Vary the length of the red and black wires on the connector. Refer to illustration. Page 6934 Page 15231 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 7033 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 1754 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 7309 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12504 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 12341 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 9714 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Page 8801 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 10532 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 15181 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 6289 4. Install the CPA retainer (5). 5. Lower the vehicle. Page 1013 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 12293 Page 6836 Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump (Diesel with 31 Series without NQZ) Fuel Pump and Sender Assembly - Front (Gas Except MEX) Page 11330 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J-26889 - Compressor . 10. Install the master cylinder to the hydraulic booster. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 11. Release the park brake and unblock the wheels. Power Brake Booster Pressure Sensor Replacement Power Brake Booster Pump Fluid Accumulator Replacement (Two-mode Hybrid) Removal Procedure Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to service the HPA. Ensure that the recommended procedures are followed to relieve system pressure, including using the manual pressure release steps. Failure to properly follow procedures to depressurize the system may result in personal injury. Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . Page 855 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended Cab with 10 Series with ASF) Page 643 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 1603 Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 19368 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 8562 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Page 20477 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 11503 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Page 18967 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 12303 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 6572 Disclaimer Page 13413 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 6549 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct (3) from the throttle body and MAF/IAT sensor. Installation Procedure Note Ensure that the notch in the air cleaner outlet duct throttle body aligns with the boss on top of the throttle body. 1. Install the air cleaner outlet duct (3) to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 16239 Disclaimer Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 6619 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16605 Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 1166 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 20592 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Page 8268 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Page 19471 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 522 Page 14054 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 17053 Remote Switch: Locations Instrument Panel/Center Console Component Views Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 3685 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair/Drive Belt Replacement) . 2. Remove the drive belt tensioner bolts (1). 3. Remove the drive belt tensioner (2). Installation Procedure 1. Install the drive belt tensioner (2). 2. Install the drive belt tensioner bolts (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 16578 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 18234 Memory Seat Module (MSM) X6 (AN3) Page 2634 Page 18212 Memory Seat Module (MSM) X7 (AN3) Page 2760 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 13328 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 20475 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 12337 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 321 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 15352 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 13718 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L and NQF/NQH) Page 807 Page 18613 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 5899 Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (1). Page 8796 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5715 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 19592 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2466 For vehicles repaired under warranty, use the table. Disclaimer Page 7433 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 13698 1 - X700 2 - Door Frame Left Rear Door Harness Routing (Crew Cab) Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Remove the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 4. Remove the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Wheel Hub/Service and Repair) . 5. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 6. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement) . 7. Separate the lower control arm from the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement) . 8. Remove the knuckle from the vehicle. Installation Procedure Page 6726 Page 191 Page 4870 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Rear of the Engine Compartment Components Floor Panel Heat Shield Replacement Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . 2. If vehicle has a regular cab, remove the exhaust heat shield nuts. 3. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 4. If vehicle has extended cab, remove the exhaust heat shield nuts. 5. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Page 6326 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Page 2847 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 7350 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 15433 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 10667 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Measure the engine movement at the engine mount in order to check for damage to the rubber portions of the mount. 1. Apply the park brake. 2. Start the engine. 3. Firmly apply and hold the primary brakes. 4. Have an assistant stand to the side of the vehicle in order to observe for engine movement. 5. Slightly load the engine shifting from drive to reverse a few times. 6. If the engine moves more than 24 mm (0.945 in) from the at rest position, in either direction, check for loose engine mount bolts. 2. If the engine mount bolt torque is within specifications, check the condition of the engine mount. 3. Replace the engine mount if any of the following conditions exist: * Heat check cracks cover the rubber cushion surface. * The rubber cushion is separated from the metal plate of the mount. * There is a split through the rubber cushion. Page 15587 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Front of Vehicle/Engine Compartment Component Views Front of the Vehicle Components (except 10 Series) Page 11873 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9369 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Page 8683 Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: Page 11129 10. Disconnect the brake master cylinder right front brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. 11. Disconnect the brake master cylinder left front brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. Page 5759 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 34 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 12809 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 7977 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 4910 Page 16426 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 9530 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 13594 Locations Oxygen Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 5264 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 10785 10. Compute the average of the first and second measurements recorded during the brake applies. Specification Maximum brake master cylinder (BMC) primary piston travel, (measured with the ignition ON, engine OFF, brake modulator and HPA depressurized, and the brakes cool), at a brake pedal apply force of 5,000 kPa (725 psi) : 18 mm (0.71 in). Warning It is recommended that you use the J-29532-A pressure bleeder or a diaphragm type (ball bleeder) which is capable of delivering 200 kPa (30 psi) for the bleed procedure. Follow and read all the directions on the Tech 2(R) for completing the Automated Bleed procedure and do every step during the bleed procedure. If you miss a step, you must start over. The EBCM Relearn will occur during the automated brake bleed procedure, so make sure you maintain battery voltage during the entire procedure. Failure to provide a constant 200 kPa (30 psi) may cause air to be trapped in the brake system and may cause brake performance problems or DTCs to occur. Tool J-29532-A has been tested extensively on this application and has proven to provide the necessary pressure and volume of brake fluid. Vacuum bleeding and other brake bleeding tools are NOT acceptable for this procedure. - If the brake pedal travel is greater than 18 mm (0.71 in), perform the following steps: 1. Inspect the brake system for leaks and visual damage. Repair or replace the components as necessary. 2. Perform the automated brake bleed procedure. Refer to Antilock Brake System Automated Bleed Procedure-Hybrid (HP2) in SI. - If the brake pedal feels spongy and/or the brake pedal travel is still excessive after performing the automated brake bleed procedure and no external brake fluid leaks or damage were found, inspect the hydraulic brake system for internal leaks, etc. Refer to Hydraulic Brake System Diagnosis (Two-mode Hybrid) in SI. 11. Clear all the codes from the modules. 12. Start the vehicle and allow the brake system to pressurize. 13. Drive the vehicle up to 32 km/h (20 mph) and perform several heavy brake stops. 14. Verify that the condition has been corrected. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8404 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 5639 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 11885 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 9060 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12443 Junction Block - Left I/P X10 (except MEX) Page 12545 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 11660 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11124 3. Disconnect the brake fluid level indicator switch electrical connector. 4. Remove the master cylinder reservoir bolts (1). 5. Carefully lift the master cylinder reservoir (1) straight upward and remove the reservoir from the master cylinder. 6. Remove the master cylinder reservoir seals (1). Installation Procedure Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 2256 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 14095 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 2061 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 2187 Sliding Rear Window Switch (A48) Window Switch - Driver X1 (A31 without AN3/DL3) Page 19786 Disclaimer Page 6589 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 2113 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13282 Page 15010 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Page 2028 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 9104 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 1005 Director, Customer and Relationship Services 09241 Page 11811 Module Circuit Function Icons Page 2687 A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 8826 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 4177 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . Page 16620 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 2292 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. If replacing the right side spark plug wire(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug wire(s) through the wheel opening. 2. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 3. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Page 13549 Page 6806 Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 6259 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 8121 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 8524 Disclaimer Page 11422 Trailer Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 15243 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 11576 10. Remove the negative battery cable assembly (1) from under the positive battery cable and from the vehicle. Installation Procedure 1. Install the negative battery cable assembly (1) to the vehicle and route the cable under the positive battery cable. Page 14961 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 16520 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Diagrams Auxiliary Water Pump: Diagrams Component Connector End Views Heater Coolant Pump (HP2) Page 4500 Drive Motor Generator Battery Control Module X4 (HP2) Page 13759 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 15088 Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 7144 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 11589 2. Install the auxiliary battery positive cable push nuts (6). 3. Install the auxiliary battery positive cable retainer (2) to the stud on the front of dash. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the auxiliary battery positive cable and nut (4) to the battery relay and tighten to 9 Nm (80 lb in) . 5. Position the auxiliary battery positive cable boot (5). 6. Connect auxiliary battery positive cable electrical connector (1) to the auxiliary battery relay. 7. Install the auxiliary battery positive cable to the mega fuse holder. 8. Install the generator battery jumper cable terminal (2) to the mega fuse stud. 9. Install the generator battery jumper cable nut (3) to the mega fuse holder and tighten to 9 Nm (80 lb in) . 10. Install the auxiliary battery positive cable nut (1) to the mega fuse holder and tighten to 9 Nm (80 lb in) . Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 5015 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: Customer Interest Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Page 15266 Page 11825 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 18746 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 7895 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Duct Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Page 6419 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 2763 Page 11042 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 12692 X110 Inline Harness Connector End Views X110 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH) Page 1618 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 20486 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10143 Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF/NQH) Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Page 14296 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 10386 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 11869 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6298 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 15599 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Page 12349 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15800 Page 5736 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10592 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Page 6450 Canister Vent Valve: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Page 20911 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 12448 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 7285 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 11118 8. Remove the antilock brake system (ABS) module splash shield retainer (1). 9. Remove the ABS module splash shield bolts (1). Page 9934 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Page 2937 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 8032 Pressure Regulating Solenoid: Service and Repair Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the range selector lever cable heat shield bolts (1). 3. Remove the range selector lever cable heat shield (2). 4. Disconnect the range selector lever cable (2) from the range select lever. 5. Remove the range selector lever cable retainer (1). 6. Remove the range selector lever cable (2) from the cable bracket. Page 16416 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 8825 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9748 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 11400 Electronic Brake Control Module (EBCM) (JL4 Except 10 Series) Page 1363 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 12. Lower the vehicle. Page 16033 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 1272 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 636 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10035 Page 16029 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Passenger Seat Components - 1 of 2 Air Inlet Valve Actuator Replacement Air Door Actuator / Motor: Service and Repair Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Page 19566 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 13694 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 16540 Disclaimer Page 8141 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 19813 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 9722 Page 6200 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 8091 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 9083 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 7819 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 1673 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 6098 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 3747 Engine Oil: Fluid Type Specifications ENGINE OIL Look for three things: 1. Use only an oil that meets GM Standard GM6094M. 2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50 or any other viscosity grade oil not recommended. 3. American Petroleum Institute (API) starburst symbol Oils meeting these requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by the vehicle warranty. COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both provide easier cold starting for the engine at extremely low temperatures. Always use an oil that meets the required specification, GM6094M. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Page 18443 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 20900 dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Windshield Washer Solvent Heater Removal WINDSHIELD WASHER SOLVENT HEATER REMOVAL 1. Disconnect the windshield wiper solvent inlet and outlet hoses (1) from the windshield washer solvent heater assembly and from the two plastic inlet and outlet windshield wiper solvent hoses. Note Do NOT remove the connector retention clips from the connectors. Do NOT remove the assembly bracket from the engine compartment. 2. Disconnect the two electrical connectors at the windshield washer solvent heater assembly. 3. Remove the windshield washer solvent heater assembly from the assembly bracket using a small flat blade screwdriver. 4. Place the windshield washer solvent heater assembly on a work bench. 5. Cut the two-wire connector from the windshield washer solvent heater assembly. Vary the length of the red and black wires on the connector. Refer to illustration. Page 10190 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 11664 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 10266 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2778 Fuse Block - Auxiliary (HP2), Bottom View Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 15045 Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch (C67) A/C Compressor Clutch (CJ2) Service and Repair Shifter Transfer Case: Service and Repair Transfer Case Control Lever Replacement Page 10305 2-3 Shift Solenoid (SS) Valve (M30) Shift Solenoid (SS) Valve 1 (MW7) Page 12634 X209 Inline Harness Connector End Views X209 Chassis Harness to Rearview Camera Jumper Harness (SVA) Page 4883 Engine Control Module (ECM) X1 (LY6) Page 4895 Engine Control Module (ECM) X2 (HP2) Page 3203 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 8814 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3780 4. If equipped with RPO LY6 (6.0L) engine, remove the oil cooler hoses from the clip. 5. Place a jack or utility stands at the rear of the vehicle. 6. If equipped, remove the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 7. For both 1500 and 2500 series, support the front differential carrier with a suitable adjustable jack. 8. For 1500 series vehicles, remove the differential carrier right side nuts. Page 4432 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 2867 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel I/P Harness Routing - Engine Compartment (Except HP2) Page 16234 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 20240 Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 8089 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 20070 Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 18773 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 1604 Page 13834 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (Except TZ0) Page 19701 Page 13200 Fuse Block - Underhood X5 Page 2083 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 8754 Page 11609 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Restraints - Air Bag Readiness Light On. Parking Brake Cable: All Technical Service Bulletins Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 13369 Junction Block - Rear Lamps X3 Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Tools Required J 41479 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the automatic transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair) . 2. Remove and discard the crankshaft rear oil seal (141). Installation Procedure Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 20582 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Passenger Door Components (except AN3/DL3) Page 4701 Voltage Inverter Module: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label Page 17192 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 18757 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 15214 Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 8. Remove the nuts (2) from the HVAC module (3). 9. Remove the bolts (1) from the HVAC module (3). 10. Remove the HVAC module (3). Installation Procedure 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the nuts (2) to the HVAC module (3). Tighten the nuts to 9 Nm (80 lb in). 4. Install the bolts (1) to the HVAC module (3). Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair )Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 3. Ensure that the sunroof does not have any air or waterleaks. Page 11081 Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Page 8887 Automatic Transmission Shift Lock Control Solenoid Automatic Transmission Turbine Speed Sensor (MW7) Page 12673 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 7963 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 17567 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Page 12682 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Page 12290 Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 1109 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 3912 20. Reposition the brake booster vacuum hose clamp at the booster. 21. Remove the brake booster vacuum hose from the booster fitting. 22. Secure the brake booster vacuum hose to the intake manifold. 23. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 24. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . Page 1263 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 8658 Disclaimer Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 5151 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. If equipped with 2 wheel drive (2WD) perform the following steps, if equipped with 4 wheel drive (4WD) proceed to step 5. 3. Remove the connector position assurance (CPA) retainer (2). 4. Disconnect the HO2S electrical connector (3) from the engine wiring harness electrical connector (5). 5. Remove the connector position assurance (CPA) retainer (2). 6. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Page 9942 Case Adapter: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Adapter Replacement Page 3016 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6366 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 4689 10. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 11. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seal. * If pressure remains at the specified value, proceed to the next step. 12. Remove all GE-48494 - adapter kit components. 13. Remove the PIM cover retaining bolts (1). 14. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 15. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Page 17382 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . Page 10810 Page 7557 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 1467 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Rear of the Engine Compartment Components Page 7504 Page 19417 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 221 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 14062 Alignment: Description and Operation Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Page 12033 Fuse Block - Underhood X1 Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 16640 For vehicles repaired under warranty, use the table. Disclaimer Page 9820 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Page 16184 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 8192 Page 8189 Switch Position Icons Page 7767 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 9280 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Page 14880 Page 9348 Actuator: Locations Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle (9.25 inch) Front Drive Axle (9.25 inch) 1 - Front Drive Axle Inner Shaft 2 - Front Drive Axle Inner Shaft Seal 3 - Front Drive Axle Inner Axle Shaft Bearing 4 - Front Drive Axle Inner Shaft Housing 5 - Front Drive Axle Clutch Gear Thrust Washer 6 - Front Drive Axle Clutch Gear 7 - Front Drive Axle Inner Shaft Retaining Ring 8 - Front Drive Axle Clutch Sleeve 9 - Front Drive Axle Clutch Shim 10 - Front Drive Axle Actuator 11 - Front Drive Axle Inner Shaft Housing Bolt 12 - Front Drive Axle Clutch Fork Assembly 13 - Front Drive Axle Clutch Fork Inner Spring 14 - Front Drive Axle Clutch Shaft Bearing 15 - Front Drive Axle Clutch Shaft 16 - Front Differential Carrier Bolt 17 - Front Differential Carrier 18 - Front Differential Carrier Half Location Pin 19 - Front Differential Case Bearing 20 - Front Differential Bearing Adjuster Nut 21 - Front Differential Bearing Adjuster Nut Sleeve 22 - Front Differential Side Bearing Cup 23 - Differential Ring Gear Bolt 24 - Front Differential Side Bearing 25 - Front Differential Pinion Gear Shaft Page 2826 Fuse Block - Mobile Radio (9L4) Page 5793 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 17693 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees . 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in) . 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft) . Page 19984 Rear Fender Clearance Lamp - Right Rear (RO5) Page 12642 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Page 10197 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9064 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3121 Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 11867 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 8704 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 11332 8. Remove and discard the HPA O-ring seal (1). 9. Remove any debris from the O-ring seal groove in the brake modulator assembly with a clean, lint-free shop cloth. 10. If replacing the HPA, properly render inert and dispose of the HPA. Refer to Power Brake Booster Pump Fluid Accumulator Disposal (See: Procedures) . Installation Procedure 1. Lubricate a new O-ring seal (1) with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the O-ring seal to the HPA. Ensure the seal is fully seated in the groove of the HPA and is not twisted. Page 16251 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 658 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 556 Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 3094 Fuse Block - I/P X3 Page 10322 Page 14496 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 12593 MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Page 19553 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Power Brake Booster Replacement (Non-Adjustable Pedals) Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Vacuum Sensor Replacement Page 1390 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10238 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster Knob Replacement - Front Page 16890 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 13160 Fuse Block - Underhood X6 Page 19418 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6679 7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow. Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 8. Pull the connection apart. Connect Procedure Warning: Refer to Fuel Pipe Fitting Warning (See: Service Precautions/Fuel Pipe Fitting Warning) . 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 11728 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 19693 Fuel Gauge Sender: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 9381 Differential Output Shaft Bearing: Service and Repair Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Page 16794 Disclaimer Page 1794 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 10342 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 5129 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 17828 Console: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Page 11056 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Page 11275 10. Using the J 37043 (1), remove the park brake cable from the backing plate. 11. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable to the vehicle. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair) . Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Page 13234 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 4449 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Diagrams Console: Diagrams Component Connector End Views Information Center Telltale Assembly (UD7) Page 12768 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Page 4890 Engine Control Module (ECM) X2 (5.3L/L76 or 6.2L Except Y91) Page 142 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: All Technical Service Bulletins Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Adjustments Axle Bearing: Adjustments Wheel Bearing Adjustment Preliminary Inspection Note Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. * Use a pry bar under the tire as an alternative. * If the wheel bearing adjustment is correct, the movement will be barely noticeable. * If the movement is excessive, adjust the bearings. Adjustment Procedure Special Tools J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Page 4012 1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the CMP actuator magnet (752) to the front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the CMP actuator magnet bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the water pump. Refer to Water Pump Replacement . A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 5953 Page 19622 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 9561 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Page 11914 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 3974 10. Remove the EN 46330 . 11. Tighten the camshaft sprocket bolt 1. Tighten the bolt a first pass to 75 Nm (55 lb ft). 2. Tighten the bolt a final pass an additional 50 degrees using J 45059 . Page 12939 Page 5120 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor (1). 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 15584 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Page 20977 Disclaimer Page 6485 11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line. 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 16. Remove the fuel line bracket bolt (1). 17. Remove the fuel/EVAP line clip nut (2). 18. Remove the fuel/EVAP line clips from the frame and crossmember. 19. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 7590 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 6061 4. Disengage the bracket retainer tabs (1) securing the ECM to the bracket. 5. Remove the ECM (3) from the bracket. Installation Procedure 1. Set the bottom of ECM into the ECM bracket tab (2). 2. Push the ECM (3) in securing the ECM to the bracket. Page 15337 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Top of the Headliner Components (Regular Cab) Page 5719 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20530 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 7450 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 5608 Page 13752 X212 Instrument Panel Harness to Instrument Panel Extension Harness (Early Production Except Y91/MEX/HP2/8S8) Locations Air Bag Deactivation Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Interior - Seat Memory Inopertive After Air Bag Deploys PROM - Programmable Read Only Memory: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Driver/Vehicle Information Display: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 1189 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 20269 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 2967 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 11684 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 13622 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 9817 Page 13633 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Page 2944 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 20930 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 4263 Water Pump: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 11417 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 6051 Engine Control Module (ECM) X2 (Diesel) Page 9557 Drive/Propeller Shaft: Fluid Type Specifications Adhesives, Fluids, Lubricants, and Sealers Lubricant ................................................................................................................................ 12345879 or equivalent meeting GM Specification 9985830 Page 10946 1. Using the J-42450-A - kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J-41013 - kit , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement) . 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner and wipe each friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) . Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JD9, JF3, JF7))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JH6, JH7)) and/orRear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JH6, JH7)) . 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. Page 7889 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 6712 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis (W/O FPCM) Fuel System Diagnosis (w/o FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Fuel Pressure Gage * J 37287 Fuel Line Shut-Off Adapters Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer toFuel System Diagnosis (w/o FPCM) Fuel System Diagnosis (w/FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 2. Ignition OFF, all accessories OFF, install theCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 3. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 8381 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 17950 Rear Window Lower Garnish Molding Replacement (Regular Cab) Rear Window Lower Garnish Molding Replacement (Regular Cab) Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Component Locations Hazard Flasher Relay: Component Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 4984 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 13797 Page 12348 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 11924 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5092 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 1015 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 19832 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 6833 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 12035 Fuse Block - Underhood X2 Page 17341 Page 3096 Page 18042 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 20829 Page 4314 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Page 7779 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 4381 Caution: During removal or installation, do not over extend the flex couple as internal damage may occur. 11. Remove the insulators (1) from the intermediate muffler assembly hangers and remove the muffler assembly. Pull the muffler assembly rearward until the flange is able to clear the front frame crossmember, and remove the muffler toward the front of the vehicle. Installation Procedure 1. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 6. 2. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. Caution: During removal or installation, do not over extend the flex couple as internal damage may occur. 3. With the aid of an assistant, position and install the muffler assembly. 4. Install the insulators (1, 2) to the front and rear muffler assembly hangers. Page 2321 Page 423 Page 18751 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 8169 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 6054 Page 15588 1 - Lower Radiator Support 2 - Inflatable Restraint Front End Sensor Front of Vehicle Components (10 Series) Page 13502 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 13577 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 6994 Ignition Coil: Service and Repair Ignition Coil Replacement Removal Procedure 1. Remove the intake manifold sight shield, as required. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. If replacing one of the rear 2 ignitions coils on the right side perform steps 3 through 13, otherwise proceed to step 14. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 3. Perform the service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 4. Disconnect the engine wiring harness electrical connector (3) from the drive motor generator power inverter module cover. 5. Loosen the drive motor generator power inverter module cover bolt (1). 6. Remove the drive motor generator power inverter module cover (2). Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 7622 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10396 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Locations Fuel Pressure Sensor/Switch: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 13411 Page 20133 Page 2666 Page 13145 Page 19449 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 15837 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 11751 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12698 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 10724 10. Remove the EBCM bolts (1). 11. Remove the EBCM (1). Installation Procedure Page 16403 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8219 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 19378 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Re-Initialization/Teach Procedure (Manual Method), possible Re-Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window reaches the vent open soft stop position and release. Press the sunroof switch - vent open and hold for approximately 10 seconds, until the window stalls at the front hard stop in the vent open position, and then moves slightly to the soft stop position. Release the button. (This is the re-initialization portion.) Continue with steps 2-4. 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion.) 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Page 20586 Power Window Switch: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 1192 Door Lock/Window Switch - Driver X3 (AN3/DL3) Page 8639 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 14481 Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (4WD 1500/2500) Page 12048 Fuse Block - I/P Top View Page 14038 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 19191 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Battery Bus Module: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 11421 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 1893 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel pressure sensor to the fuel line and tighten the sensor to 15 Nm (11 lb ft) . 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Page 19447 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11747 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Diagrams Audible Warning Device: Diagrams Component Connector End Views Backup Alarm (8S3) Page 18534 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 7911 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 8433 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 481 Page 18673 Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Page 20201 Page 20199 Page 10168 Switch Position Icons Page 20030 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 10403 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 18993 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 3037 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Page 12272 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 13368 Junction Block - Rear Lamps X2 Page 7891 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 3040 Page 4787 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 11079 Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Page 20498 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 8122 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 3868 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gage Adapter * J 21867 Pressure Gage 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 3. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 4. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 5. Listen for a noisy valve train or a knocking noise. 6. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil) . * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 7. Remove the oil filter and install the EN-47971 (1). 8. Install the J 21867 (2), or equivalent to the EN-47971 (1). 9. Run the engine and measure the engine oil pressure. 10. Compare the readings to Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications/Engine Mechanical Specifications) . 11. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul) . * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul) . * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul) . * Improper operation of the active fuel management oil pressure relief valve Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Page 14523 6. Install the NEW shock absorber nut (1) and tighten. * For vehicles equipped with electronic suspension, tighten the shock absorber nut to 50 Nm (37 lb ft) . * For vehicles equipped with electronic suspension, tighten the electrical connector to 17 Nm (13 lb ft) . * For vehicles without electronic suspension, tighten the shock absorber nut to 60 Nm (44 lb ft) . 7. Remove the shock absorber assembly from the spring compressor 8. Install the shock absorber in the vehicle. Refer to Shock Absorber and Spring Assembly Replacement (See: Shock Absorber and Spring Assembly Replacement) . Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber and Spring Assembly Replacement Shock Absorber and Spring Assembly Replacement Page 9080 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 11748 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 13717 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L Except NQF/NQH/HP2) Page 9283 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Page 11746 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 10176 Devices and Sensors Page 15706 Inflatable Restraint Sensing and Diagnostic Module (SDM) (MEX) Page 13688 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 12400 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 6037 Engine Control Module (ECM) X1 (Gas Except 4.3L/LY6/HP2) Page 16928 Parking Assist Control Module: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 19865 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 4693 board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 7. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. 8. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 9. Rotate the drive motor generator control module assembly onto the PIM cover. 10. Remove the APM to PIM mounting fasteners (1). 11. Remove the APM (2) and discard the coolant seal (3). Installation Procedure Page 14975 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 3988 15. Tighten the CMP actuator solenoid valve. 1. Tighten the bolt a first pass to 65 Nm (48 lb ft). 2. Tighten the bolt a final pass an additional 90 degrees using J 45059 . 16. Remove the J 42386-A (1) and bolts. 17. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . Page 10511 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 13310 Page 20489 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 15805 Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Hydraulic Brake Booster Replacement Hydraulic Brake Booster: Service and Repair Hydraulic Brake Booster Replacement Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Brake Pipe Replacement (Master Cylinder to ABS Controller))Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7))Rear Brake Hose Replacement (Frame to Axle - JD9, JF3, w/JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (2500 Series))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JD9)) * Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement () * Brake Pressure Modulator Valve Replacement () 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 14909 Air Duct: Service and Repair Air Inlet Assembly Replacement Air Inlet Assembly Replacement Page 12619 X150 Inline Harness Connector End Views X150 Engine Harness to I/P Harness (HP2) Page 5202 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 13731 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 9505 Note Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. Page 13066 Page 15954 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness. 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector (1) to the adapter (2) on the deployment harness (3). Note When deploying a seat belt pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. Page 141 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 19642 Page 4994 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 9259 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Page 1477 Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 18457 Memory Seat Module (MSM) X3 (AN3) Page 2506 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Page 12408 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 12260 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Fuse Block Jumper Harness Routing (9L4) Page 3073 Page 14311 Steering Control Module: Service and Repair Electronic Power Steering Motor Control Module Replacement Page 12599 Page 19141 Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement (Pickup Box) Pickup Box Endgate Striker Replacement (Pickup Box) Page 19814 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Page 13068 Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Interior - Cleaning Interior Surfaces of Vehicle Carpet: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 650 Body Control Module (BCM) X5 Page 13415 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 5042 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 5492 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 12172 Fuse Block - Auxiliary (HP2), Bottom View Page 5282 * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 . 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Remove the J 37287 andCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal ). 5. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system components test normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Fuel System Diagnosis (W/FPCM) Page 17861 Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Page 12066 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 5945 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 20588 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 8321 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 20259 Page 7111 Switches and Relays Page 4144 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 20600 Window Switch - Driver X2 (A31 without AN3/DL3) Page 3944 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Page 15320 Page 3662 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 5163 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 4550 16. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 17. Clean the sealing surface of the PIM cover as necessary. 18. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 19. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . Page 12252 Junction Block - Rear Lamps X2 Page 5776 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation) . GMLAN Connector Terminal Repair Page 5491 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 6032 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (4.3L) Page 18917 For vehicles repaired under warranty, use the table. Disclaimer Page 18783 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 12005 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8865 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 14559 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Bore Diameter.............................................................................................. .............................69.871-69.889 mm (2.75-2.751 in) Crankshaft Main Bearing Bore Out-of-Round.. ......................................................................................................................................0.006 mm (0.0002 in) Crankshaft Main Bearing Clearance Production.............................................................................................................0.02-0.052 mm (0.0008-0.0021 in) Crankshaft Main Bearing Clearance Service...................................................................................................................0.02-0.065 mm (0.0008-0.0025 in) Crankshaft Main Journal Diameter Production.............................................................................................................64.992-65.008 mm (2.558-2.559 in) Crankshaft Main Journal Diameter - Service............................................................. .............................................................................64.992 mm (2.558 in) Crankshaft Main Journal Out-of-Round Production........................................................................................................................0.003 mm (0.000118 in) Crankshaft Main Journal Out-of-Round Service..................................................................................................................................0.008 mm (0.0003 in) Crankshaft Main Journal Taper - Production...................................................................... .....................................................................0.01 mm (0.0004 in) Crankshaft Main Journal Taper - S ervice...............................................................................................................................................0.0 2 mm (0.00078 in) Crankshaft Rear Flange Runout............................................................................. .....................................................................................0.05 mm (0.002 in) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter.............................................................................0.7 mm (0.028 in) Crankshaft Thrust Surface - Production............................................................................................................................. 26.14-26.22 mm (1.029-1.0315 in) Crankshaft Thrust Surface - Service............................................. ..........................................................................................................26.22 mm (1.0315 in) Crankshaft Thrust Surface Runout....................................................................................................... ....................................................0.025 mm (0.001 in) Crankshaft Bearing Cap M8 Bolts........................................................................................................ ..........................................................25 Nm (18 lb ft) Crankshaft Bearing Cap M10 Bolts - First Pass in Sequence..........................................................................................................................20 Nm (15 lb ft) Crankshaft Bearing Cap M10 Bolts - Final Pass in Sequence..................................................................................................................................80 degrees Crankshaft Bearing Cap M10 Studs - First Pass in Sequence.........................................................................................................................20 Nm (15 lb ft) Crankshaft Bearing Cap M10 Studs - Final Pass in Sequence.............................................................................................................................51 degrees Page 1729 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 3002 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 20186 Page 17493 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Page 7311 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 7297 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 5227 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 20992 Page 790 Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 11956 Branching Point: Diagrams JX223 Splice Pack Connector End Views JX223 (U2K/UK6/UE1 without Y91) Page 16047 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 8065 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 4509 15. Install the 3 phase cable retainer (1) to the bracket. 16. Install the 3 phase cable retainer nut (2). Tighten the nut to 9 Nm (80 lb in). 17. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6). 18. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten the mounting fastener to 9 Nm (80 lb in). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 19. Install the PIM 3 phase cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in). Page 10327 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 9384 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . Page 13863 Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 5609 Engine Control Module (ECM) X2 (HP2) Page 1892 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. 4. Remove the fuel pressure sensor from the fuel line. 5. Remove and discard the fuel pressure sensor O-ring seal. Installation Procedure Page 14922 Page 19314 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2223 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 11752 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 10901 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 10659 Page 882 Electronic Power Steering Motor Control Module X4 (HP2) Page 7432 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 4034 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4 - 310.3 kPa (43 - 45 psi). Circuit/System Testing Important: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from theCH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with theCH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer toSymptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (2500/3500 Regular Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Crew Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Regular Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Extended Cab) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp clip (2) from the air cleaner outlet duct (1). Page 6736 10. Remove the CPA retainer. 11. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 12. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control. 13. Disconnect the engine wiring harness electrical connectors (5) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 14. Remove the engine wiring harness clip (4) from the ignition coil bracket stud. Note The auxiliary heater water pump hose and the surge tank outlet hose do not need to be removed from the bracket in order to reposition the bracket. 15. Remove the heater hose bracket nut (2) and bracket (1). Reposition the bracket out of the way. Hoses shown removed for clarity. Page 6954 Page 4902 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Disengage the engine wiring harness electrical connector retainers and remove the connectors (2) from the ECM (1). Page 9565 Ping, Snap, or Click Noise Ping, Snap, or Click Noise Scraping Noise Scraping Noise Locations Rear Door Window Glass: Locations Harness Routing Views Sliding Rear Window Jumper Harness Routing (A48) 1 - X320 2 - Rear Window 3 - J336 (except C49) 4 - J335 (except C49) Left and Right Hip Lamp Harness Routing (R05) Page 16244 Disclaimer Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Page 14200 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair ). Page 20688 For vehicles repaired under warranty, use the table. Disclaimer Page 19035 A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 241 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 5178 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Page 5070 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Page 11558 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 20376 Page 9011 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 4159 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 13344 Page 1133 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 11402 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Page 19911 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 4917 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 12289 Switches and Relays Page 7121 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 17443 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 5014 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 12136 Page 13313 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 13044 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 3371 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 5707 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 14389 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 1815 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (6.0L with ZW9) Page 6741 Push down firmly on both sides of the rail until all injectors have been seated into their bores. 8. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 9. Install the EVAP tube and purge solenoid. 10. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 11. Connect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . Page 18674 Rear Seat Cushion Frame Replacement (Extended Cab with A68) Rear Seat Cushion Frame Replacement (Extended Cab with A68) Page 7419 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Page 16967 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 2128 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Page 20889 Page 6731 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (Gas with LY6) Page 11823 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7167 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12178 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 1515 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 17195 Trailer Connector: Connector Locations Harness Routing Views Camper Harness Routing and Chassis Harness Routing - Rear 1 - X414 (UY2/8S3) 2 - J420 (UY2) 3 - Camper/Trailer Harness 4 - J415 (UY2) 5 - Chassis Harness 6 - J416 (UY2) 7 - J417 (UY2) 8 - J414 (UY2) 9 - J421 (UY2) 10 - J410 (UY2) 11 - Blunt Cut - Camper Trailer Provision (UY2) 12 - G401 (except LY6/LMM) 13 - Trailer Connector (UY7) Page 10468 Transfer Case Actuator: Locations MP 1625/1626-NQF - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 - Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor - O-Ring - Seal 15 - Transfer Case Rear Half 16 Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 22 - Transfer Case Two/Four Wheel Drive Actuator Assembly 23 - Transfer Case Two/Four Wheel Drive Actuator Seal Page 8822 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 18796 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 6926 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Transmission 5 Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 X175 (MW7) Page 11357 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Diagrams License Plate Lamp: Diagrams Component Connector End Views License Lamp - Left License Lamp - Right Page 7697 Pressure Regulating Solenoid: Service and Repair Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the range selector lever cable heat shield bolts (1). 3. Remove the range selector lever cable heat shield (2). 4. Disconnect the range selector lever cable (2) from the range select lever. 5. Remove the range selector lever cable retainer (1). 6. Remove the range selector lever cable (2) from the cable bracket. Page 6694 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 19763 Disclaimer Page 644 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 6910 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 7098 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 3772 11. Install the engine oil cooler hose/pipe adapter bolts (2) and: Tighten Tighten the bolts to 12 Nm (106 lb in). 12. Install the engine oil cooler hose/pipe retaining bracket bolt (1) and: Tighten Tighten the bolt to 25 Nm (18 lb ft). 13. Verify the correct engine oil level. 14. Verify the repair. Refer to Oil Leak Diagnosis in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 1678 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 8143 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3950 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Place a suitable drain pan under the oil pan drain plug. 3. Remove the oil pan drain plug (430). 4. Allow the oil pan to drain completely. 5. Re-install the oil pan drain plug until snug. 6. Remove the drain pan from under the vehicle. 7. Disconnect the engine harness electrical connector (1) from the oil level sensor. Page 14216 4. Place scaleJ 35999 near the relay rod end of the idler arm. 5. Exert a 110 Nm (25 lb) force upward and then downward while measuring the total distance the idler arm moves. 6. If the movement exceeds 2 mm (0.078 in) then replace the idler arm. Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 8434 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 18841 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 20220 Hazard Flasher Relay: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 8859 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 6849 Page 14208 1. Position the relay rod (5) in the vehicle. 2. Install the pitman arm (2) to the relay rod (5). 3. Install the idler arm (1) to the relay rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install a NEW pitman arm nut (4) and tighten to 62 Nm (46 lb ft) . 5. Install a NEW idler arm nut (6) and tighten to 62 Nm (46 lb ft) . 6. Install the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 7. Install the steering linkage shock absorber to the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair) . 8. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 9. Measure the wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement) . 10. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Page 10200 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Underhood Fuse Block Fuel Pump Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 3956 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 12700 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Page 16655 Amplifier: Service and Repair Radio Speaker Amplifier Replacement Page 7724 Page 11853 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 19571 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15955 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness. 18. Place a 12 volt minimum/2 amp minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt pretensioner as soon as possible. 25. Dispose of the deployed seat belt pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the seat belt pretensioners inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: * The vehicle has completed its useful life. * Irreparable damage occurs to the vehicle in a non-deployment type accident. * Irreparable damage occurs to the vehicle during a theft. * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. Page 15068 Page 15995 Page 1816 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 16481 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 9015 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 3429 Valve Deactivation Solenoid: Description and Operation Cylinder Deactivation (Active Fuel Management) System Description To provide maximum fuel economy under light load driving conditions, the engine control module (ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1, 7, 6, and 4, switching to a V4 mode. The engine will operate on 8 cylinders or V8 mode, during engine starting, engine idling, and medium to heavy throttle applications. When cylinder deactivation is commanded, the ECM will determine what cylinder is firing, and begin deactivation on the next closest deactivated cylinder in firing order sequence. For example, if cylinder number 1 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 4. Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing contacts the camshaft lobe through a roller. During V8 mode, when all cylinders are active, the locking pins are pushed outward by spring force, locking the pin housing and outer housing together causing the lifter to function as a normal lifter. When cylinder deactivation is commanded ON, the locking pins are pushed inward with engine oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter pin housing is unlocked from the outer housing, the pin housing will remain stationary, while the outer housing will move with the profile of the camshaft lobe, which results in the valve remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking pins used for cylinder deactivation. Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM, the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation is timed so that the cylinder is on an intake event. During an intake event, the intake CAM lobe is pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them from moving until the intake valve has closed. When the intake valve lifter reaches the base circle of the Page 13059 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 20587 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Page 7335 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 18568 Service and Repair Parking Brake Actuator: Service and Repair Parking Brake Actuator Replacement (JD9) Locations Steering Mounted Controls Assembly: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 13238 Page 11898 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10353 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 18264 Page 10124 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 7275 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4053 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Engine - Valve Lifter Tick Noise At Start Up Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 20490 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13245 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Underhood Fuse Block UNDERHOOD FUSE BLOCK The underhood fuse block is located in the engine compartment, on the driver side of the vehicle. Lift the cover to access the fuse block. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. To remove fuses, hold the end of the fuse between your thumb and index finger and pull straight out. Rear Seat Latch Replacement (Extended Cab with AM7) Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with AM7) Rear Seat Latch Replacement (Extended Cab with AM7) Page 10979 4. Spread the brake shoes apart slightly and remove the brake shoe adjuster (1). 5. Inspect and replace any missing, worn, or damaged drum brake adjuster hardware. Refer to Drum Brake Adjusting Hardware Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Drum Brake Adjusting Hardware Inspection) . 6. Remove the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to remove from the hold down pins. Page 5859 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 6869 Page 14572 * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 17494 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Page 6782 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft). 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 15. Lower the vehicle. 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 19. Install the fuel fill cap. 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( Page 4198 Page 3467 7. Compress the timing chain tensioner guide and install the EN 46330 . Note * Properly locate the CMP actuator onto the locating pin of the camshaft. * The sprocket teeth and timing chain teeth must mesh. * The camshaft and the crankshaft sprocket alignment mark MUST be aligned properly. * Do not use the CMP solenoid valve again. Install a NEW valve during assembly. 8. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Page 452 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control module electrical connector. Note It is not necessary to completely remove the bolts. 4. Reach above the trailer brake control module and relay bracket and loosen, but do not remove, the trailer brake control module bolts (1). Page 3566 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools * J 41478 Crankshaft Front Oil Seal Installer * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-A Crankshaft Balancer Remover * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the air conditioning (A/C) drive belt. Refer to Air Conditioning Compressor Belt Replacement (V8) (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Air Conditioning Compressor Belt Replacement) . 2. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 3. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Page 856 Page 10188 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11849 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 14197 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 14225 Pitman Arm: Service and Repair Pitman Arm Replacement Special Tools * J 6632-01 Pitman Arm Puller * J 29107-A Pitman Arm Puller Removal Procedure 1. Remove the steering gear. Refer to Steering Gear Replacement (Two Mode Hybrid) (See: Steering Gear/Service and Repair)Steering Gear Replacement (Non-Rack and Pinion) (See: Steering Gear/Service and Repair)Steering Gear Replacement (Rack and Pinion) (See: Steering Gear/Service and Repair) . 2. Place the steering gear into a vise. 3. Remove the pitman arm nut (1) and washer (2). 4. Remove the pitman arm from the pitman arm shaft using pullerJ 6632-01 or pullerJ 29107-A . Installation Procedure 1. Install the pitman arm onto the steering gear. Page 4265 Generator Battery Vent Fan (HP2) Generator Battery Vent Fan Relay (HP2) Locations Canister Vent Valve: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 13204 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 15993 Page 12982 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12968 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 10258 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Page 20948 1. Transfer washer pumps and level indicator to the new washer solvent container. 2. Install the windshield washer container assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the upper windshield washer solvent container bolts. Tighten the bolts to 9 Nm (80 lb in). 4. Install the auxiliary battery tray, if equipped. Refer to Auxiliary Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Auxiliary Battery Tray Replacement) . 5. Connect the electrical connectors. 6. Connect the washer pump hoses (1, 2). Refer to Windshield Washer Hose Replacement (See: Windshield Washer Hose/Service and Repair) . 7. Install the lower outer washer container bolt. 8. Install the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . Page 17127 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 435 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 439 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 12569 Disclaimer Page 593 Page 11408 10. Remove the EBCM bolts (1). 11. Remove the EBCM (1). Installation Procedure Page 13131 Fuse Block - Auxiliary (HP2), Bottom View Page 2669 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 8849 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1569 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Page 18870 Heated/Cooled Seat - Driver (KB6) Page 12285 Harness Components Page 10058 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 18816 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 11681 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 20532 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 14954 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 17350 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 10928 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 19611 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 11452 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Power Brake Booster Vacuum Sensor Replacement Removal Procedure 1. Disconnect the chassis wiring harness electrical connector (1) from the brake booster vacuum sensor. 2. Remove the brake booster vacuum sensor from the brake booster. 3. Remove the brake booster vacuum sensor grommet from the brake booster. Installation Procedure Important: Lightly coat the brake booster vacuum sensor grommet with clean engine oil before installing the sensor. Page 15249 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Low Pressure Sensor (HP2) A/C Low Pressure Switch Page 10900 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Page 20870 Note Remove the two relays (1) next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse (2) using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays (1) removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure that the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this buleltin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Buick Lucerne, Cadillac DTS and CTS 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of the engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "JC1", which is positioned in the rear center quadrant of the UBEC. 2008-2009 Buick Lucerne and Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "F28", which is positioned in the rear inside quadrant of the UBEC. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 13227 Junction Block - Left I/P X7 (JF4) Page 10999 36. Press Start to begin the next bleed sequence. The brake modulator to master cylinder, or intermediate, brake circuits are being port bled during this sequence. Ensure each of the 2 intermediate brake pipe ports (1) is fully bled and securely tightened before the 60-second cycle is completed. 37. Loosen, but do not disconnect, one of the 2 intermediate brake pipe fittings (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 38. Tighten the first brake pipe fitting, then loosen, but do not disconnect, the second intermediate brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 39. Tighten the second intermediate brake pipe fitting. 40. If both of the intermediate brake pipe ports (1) were not fully bled within the 60-second cycle time, press Start to repeat Steps 37-39. 41. Press Enter to continue. The brake master cylinder to brake modulator, or primary, brake circuit is being port bled during this sequence. Ensure the primary brake pipe port (1) is fully bled and securely tightened before the 60-second cycle is completed. 42. Loosen, but do not disconnect, the primary brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 43. Tighten the primary brake pipe fitting (1). Page 4641 Drive Motor Control Module: Service and Repair Drive Motor Generator Power Inverter Module Removal and Installation Drive Motor Generator Power Inverter Module Removal and Installation Special Tools * GE-48494 - Power Electronics Pressure Test Adapter Kit * J 24460-01 - Cooling System Pressure Tester Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 3. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. Page 7815 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13136 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 19549 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 12663 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) Page 3512 1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the CMP actuator magnet (752) to the front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the CMP actuator magnet bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the water pump. Refer to Water Pump Replacement . Page 1865 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 3049 Junction Block - Left I/P X10 (except MEX) Page 19454 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 20834 Page 3053 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 4659 Drive Motor Control Module: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 16957 Disclaimer Page 8098 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 13854 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Console Harness (Y91/UQA/D07) Page 18313 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 739 Engine Control Module (ECM) X2 (4.3L) Page 12362 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 12940 Devices and Sensors Page 20089 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15074 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. 10. Remove the condenser from the vehicle. Installation Procedure Note If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities (Non-HP2) () for system capacity information. 1. Install the condenser to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper insulator retainers and the insulator retainer bolts and tighten to 2.4 Nm (21 lb in) . 3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement) . 4. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft) . 5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement) . 6. Install the compressor discharge hose nut to the condenser and tighten to 16 Nm (12 lb ft) . Page 15054 Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 17264 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement (Chevrolet) Front Bumper Impact Bar Extension Replacement (Chevrolet) Page 20386 Tail/Stop and Turn Signal Lamp - Lower Right Page 4336 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7277 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8971 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12794 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 7857 Page 18207 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 10735 18. Through the frame crossmember, remove the BPMV bracket bolts (1). 19. Loosen, but do not remove, the lower BPMV bracket bolt (1). Page 17542 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 2006 Seat Occupant Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 10271 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Engine Mount and Bracket Replacement - Left Engine Mount: Service and Repair Engine Mount and Bracket Replacement - Left Engine Mount Bracket Replacement - Left Side Removal Procedure 1. Remove the engine mount. Refer to Engine Mount Replacement - Left Side (1500 LY2) (See: )Engine Mount Replacement - Left Side (1500 Except RPOs LY6, LY2) (See: )Engine Mount Replacement - Left Side (2500 LY6) (See: ) . 2. Remove the engine mount bracket bolts. 3. Remove the engine mount bracket. Installation Procedure 1. Position the engine mount bracket onto the frame. 2. Perform the following steps prior to installing the engine mount bracket bolts. Page 10371 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13176 Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 19492 ‹› If less than the specified value, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM. 3. Test for B+ between the B+ circuit terminal 1 and the signal circuit terminal 3. ‹› If less than the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 4. Ignition OFF, disconnect the X1 harness connector at the BCM. 5. Test for infinite resistance between the signal circuit terminal 3 and ground. ‹› If less than the specified value, test the signal circuit for a short to ground. 6. If all circuits test normal, test or replace the steering wheel control switch-left. Component Testing 1. Disconnect the harness connector at the steering wheel controls switch - left. 2. Cruise control switch ON, measure the resistance between terminal 1 and terminal 3 while individually activation and holding each cruise control function switch and compare the resistance reading to the values in the table below. ‹› If not within the specified resistance range, replace the steering wheel controls switch - left. Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup, and programming Page 13448 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14809 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 7352 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 11071 Rear Brake Hose Replacement (2500 Series) Rear Brake Hose Replacement (Caliper - JD9) Page 7148 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 7142 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Body - Incorrect Sun Visor Label Child Seat: Customer Interest Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 18612 Page 2755 Page 10020 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Page 2570 10. Compute the average of the first and second measurements recorded during the brake applies. Specification Maximum brake master cylinder (BMC) primary piston travel, (measured with the ignition ON, engine OFF, brake modulator and HPA depressurized, and the brakes cool), at a brake pedal apply force of 5,000 kPa (725 psi) : 18 mm (0.71 in). Warning It is recommended that you use the J-29532-A pressure bleeder or a diaphragm type (ball bleeder) which is capable of delivering 200 kPa (30 psi) for the bleed procedure. Follow and read all the directions on the Tech 2(R) for completing the Automated Bleed procedure and do every step during the bleed procedure. If you miss a step, you must start over. The EBCM Relearn will occur during the automated brake bleed procedure, so make sure you maintain battery voltage during the entire procedure. Failure to provide a constant 200 kPa (30 psi) may cause air to be trapped in the brake system and may cause brake performance problems or DTCs to occur. Tool J-29532-A has been tested extensively on this application and has proven to provide the necessary pressure and volume of brake fluid. Vacuum bleeding and other brake bleeding tools are NOT acceptable for this procedure. - If the brake pedal travel is greater than 18 mm (0.71 in), perform the following steps: 1. Inspect the brake system for leaks and visual damage. Repair or replace the components as necessary. 2. Perform the automated brake bleed procedure. Refer to Antilock Brake System Automated Bleed Procedure-Hybrid (HP2) in SI. - If the brake pedal feels spongy and/or the brake pedal travel is still excessive after performing the automated brake bleed procedure and no external brake fluid leaks or damage were found, inspect the hydraulic brake system for internal leaks, etc. Refer to Hydraulic Brake System Diagnosis (Two-mode Hybrid) in SI. 11. Clear all the codes from the modules. 12. Start the vehicle and allow the brake system to pressurize. 13. Drive the vehicle up to 32 km/h (20 mph) and perform several heavy brake stops. 14. Verify that the condition has been corrected. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15619 Page 4415 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 4912 Page 7413 23 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 24 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 25 - Transfer Case Oil Pump Assembly 26 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 27 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 28 - Transfer Case Rear Output Shaft Rear Bearing Assembly 29 Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 30 - Transfer Case Oil Pump Suction Pipe Seal 31 - Transfer Case Oil Pump Suction Pipe 32 - Transfer Case Front Output Shaft Rear Bearing Assembly 33 - Transfer Case Front Output Shaft Driven Sprocket Spacer 34 Transfer Case Front Output Shaft Driven Sprocket 35 - Transfer Case Front Output Shaft Hole Plug 36 - Transfer Case Front Output Shaft 37 - Transfer Case Front Output Shaft Front Bearing Assembly Clutch Components Page 16651 Amplifier: Diagrams Component Connector End Views Audio Amplifier X1 (UQA with Y91) Audio Amplifier X1 (UQA without Y91) Page 3145 procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 16036 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Interior - Lint Accumulation On Ebony Colored Seats Seat Cover: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 9854 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 6798 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Page 3068 Page 3862 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 532 Page 17070 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 11945 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Accessory Power Outlet - Center Seat (AZ3) Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 15654 Disclaimer Page 13015 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13287 Fuse Block - Auxiliary (HP2), Top View Page 13297 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11865 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 3712 Refer to Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See: Testing and Inspection/Component Tests and General Diagnostics) . Page 4579 Voltage Inverter Module: Diagrams Component Connector End Views Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Page 12274 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components Page 3285 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 6095 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 11767 Charging System Operation The purpose of the charging system is to maintain the battery charge and vehicle loads. There are 6 modes of operation and they include: * Battery Sulfation Mode * Normal Mode * Fuel Economy Mode * Headlamp Mode * Voltage Reduction Mode * Plant Assembly Mode Battery Sulfation Mode The BCM will enter this mode when the interpreted charging system voltage is less than 13.2 volts for 30 minutes. When this condition exists the BCM will enter Normal Mode for 5 minutes. The BCM will then determine which mode to enter depending on voltage requirements. Normal Mode The BCM will enter Normal Mode when ever one of the following conditions are met. * The wipers are ON for more than 3 seconds. * GMLAN Climate Control Voltage Boost Mode Request is true, as sensed by the HVAC control head. High speed cooling fan, rear defogger and HVAC high speed blower operation can cause the BCM to enter the Charge Mode. * The estimated battery temperature is less than 0°C (32°F). * Vehicle Speed is greater than 145 km/h (90 mph) * Current Sensor Fault Exists * System Voltage was determined to be below 12.56 volts * Tow/Haul Mode is enabled When any one of these conditions is met, the system will set targeted generator output voltage to a charging voltage between 13.9-15.5 volts, depending on the battery state of charge and estimated battery temperature. Fuel Economy Mode The BCM will enter Fuel Economy Mode when the ambient air temperature is at least 0°C (32°F) but less than or equal to 80°C (176°F), the calculated battery current is greater than -8 amps but less than 5 amps, and the battery state of charge (SOC) is greater than or equal to 85 percent. Its targeted APM set-point voltage is the open circuit voltage of the battery and can be between 12.6-13.2 volts. The BCM will exit this mode and enter Normal Mode when any of the conditions described above are present. Headlamp Mode The BCM will enter Headlamp Mode when ever the high or low beam headlamps are ON. Voltage will be regulated between 13.9-14.5 volts Voltage Reduction Mode The BCM will enter Voltage Reduction Mode when the calculated battery temperature is above 0°C (32°F) and the calculated battery current is greater than -7 amps but less than 1 amp. Its targeted APM set-point voltage is 12.9-13.2 volts. The BCM will exit this mode once the criteria are met for Normal Mode. Plant Assembly Mode The BCM will increase charging voltage for the first 500 miles of operation in an effort to ensure that the 12 volt battery is fully charged when the vehicle is delivered to the customer. Instrument Panel Cluster (IPC) Operation Charge Indicator Operation The instrument panel cluster (IPC) illuminates the charge indicator and displays a warning message in the driver information center (DIC) when the one or more of the following occurs: * The engine control module (ECM) detects system voltage less than 11 volts or greater than 16 volts. The IPC receives a GMLAN message from the ECM requesting illumination. * The BCM determines that the system voltage is less than 11 volts or greater than 16 volts. * The IPC receives a GMLAN message from the body control module (BCM) indicating there is a system voltage range concern. Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: All Technical Service Bulletins Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 7720 Page 19509 Switch Position Icons Page 17093 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 7894 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 11796 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 11739 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 8202 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Service and Repair Expansion Block/Orifice Tube: Service and Repair Expansion (Orifice) Tube Replacement Page 9036 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Locations Hybrid Battery Service Switch: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 14832 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Page 2983 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6776 17. Remove the caps from the fuel rail and EVAP line. 18. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 19. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 20. Install the fuel fill cap. 21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 22. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 23. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 13116 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 18226 Page 11441 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) Page 10379 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 15009 Page 6107 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 8819 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 1720 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 10118 1. Install the control rod onto the control lever first. 2. Slide the control rod forward. 3. Install the control rod onto the shift control lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the control rod adjusting bolt. Tighten the bolt to 15 Nm (11 lb ft). 5. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . Page 7652 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 5949 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 17722 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control relay electrical connector. Note It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Page 11496 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (Except 10 Series) Page 20894 Note Remove the two relays (1) next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse (2) using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays (1) removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure that the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this buleltin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Buick Lucerne, Cadillac DTS and CTS 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of the engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "JC1", which is positioned in the rear center quadrant of the UBEC. 2008-2009 Buick Lucerne and Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "F28", which is positioned in the rear inside quadrant of the UBEC. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 3004 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 8146 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 8980 Page 6570 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 4103 Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Page 1248 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8642 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 256 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 8008 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD and SHD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Inserts 12 - Transfer Case Shift Fork Spring 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case High/Low Shift Fork 15 - Transfer Case High/Low Shift Fork Inserts 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case Shift Detent Lever Assembly 18 - Transfer Case Rear Output Shaft 19 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 20 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 21 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 22 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Outer Page 12397 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11014 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Page 3814 Disclaimer Page 18276 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Page 7347 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11119 10. Remove the ABS module splash shield (1). 11. Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake hose fittings. 12. Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination. Page 2883 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Left Rear of the Engine Compartment Components Page 5212 1 - Fuel Injector 2 2 - Turbocharger Vane Position Sensor 3 - Fuel Injector 4 4 - Fuel Rail Pressure (FRP) Sensor 5 - Fuel Injector 6 6 - Fuel Injector 8 7 - Glow Plug 8 8 - Glow Plug 6 9 - Engine Oil Pressure (EOP) Sensor 10 - Engine Oil Level (EOL) Switch 11 - Glow Plug 4 12 - G106 13 - G102 14 - Glow Plug 2 Top of the Engine Components (Diesel) Page 13353 Junction Block - Left I/P X10 (except MEX) Page 19467 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 8723 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8145 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7970 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17986 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 20667 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 18066 Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 16233 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 15549 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab with 10 Series with ASF) Page 14524 Page 2326 Page 12947 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 6023 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 3696 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the engine mount to engine bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Using the adjustable jack, lower the engine until the engine mount is sitting flush on the frame. 4. Remove the adjustable jack from the engine block. 5. Install the left side exhaust manifold heatshield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (4.3L) ()Exhaust Manifold Heat Shield Replacement - Left Side (4.8L, 5.3L, 6.0L, and 6.2L) () . 6. Lower the vehicle. 7. Install the engine mount to frame bolts (1). Tighten the bolts to 65 Nm (48 lb ft) starting with the middle bolt then either side bolt. 8. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Page 12065 Page 9072 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LFA) engine, the park position for the CMP actuator and camshaft is 14.5 degrees after top dead center (ATDC), or 29 crankshaft degrees ATDC. The engine control module (ECM) can only command the CMP actuator to advance the valve timing from the park position, or retard the valve timing back to the park position. The total range of valve timing authority is 23 degrees camshaft rotation, or 46 degrees of crankshaft rotation. The control range is from the park position of 14.5 degrees camshaft, or 29 degrees crankshaft ATDC, to 8.5 degrees camshaft or 17 degrees crankshaft before top dead center (BTDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for CAM advance and a passage for CAM retard. The camshaft actuator is attached to the front of the camshaft, and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature, engine oil level, and aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostic The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control, DTC P0010 will set. Page 14262 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 12049 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 6591 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Locations Hazard Warning Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 15979 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 8844 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10171 Page 11855 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8225 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 13874 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Page 19628 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 1695 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2780 Page 1437 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 19452 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 13350 Junction Block - Left I/P X7 (JF4) Diagrams Center Mounted Brake Lamp: Diagrams Component Connector End Views Center High Mounted Stop Lamp (CHMSL) X1 Center High Mounted Stop Lamp (CHMSL) X2 Center High Mounted Stop Lamp (CHMSL) X3 Page 19483 Cruise Control: Electrical Diagrams Cruise Control Schematics Page 11673 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 20473 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 6761 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. 13. Install the fuel pipe bracket nut to the bellhousing stud and tighten the nut to 25 Nm (18 lb ft) . 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 15. Lower the vehicle. Service and Repair Tie Down Hook / Bracket: Service and Repair Pickup Box Tie Down Loop Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning) . 1. Locate and drill out the spot welds. 2. Remove the tie down loop. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair () . Page 11644 Charging System: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7739 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20451 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 6751 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1) and tighten to 9 Nm (80 lb in) . 5. Install the fuel/EVAP line clip nut (2) and tighten to 20 Nm (15 lb ft) . 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. Page 1954 Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99/MEX) Page 12594 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 11123 8. Connect the brake master cylinder reservoir return hose quick connect (1). 9. Connect the brake master cylinder reservoir supply hose quick connect (2). 10. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Procedures/Master Cylinder Replacement (Vacuum Boost)) . Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement (JH6, JH7) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . 1. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. 2. Discard the brake fluid into an approved container. Page 5325 4. Brush or using compressed air, blow away any dirt from around the spark plug. 5. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Hybrid Controls Electronic Component Views Voltage Inverter Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 4592 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 8643 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Page 13796 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Page 19455 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 12486 Page 12214 Fuse Block - Auxiliary (HP2), Bottom View Page 2060 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Page 10230 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3221 Frequently Asked Questions Disclaimer Page 525 Page 220 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 13910 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 16315 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair/Drive Belt Replacement) . 2. Loosen the drive belt idler pulley bolt (1). 3. Remove the drive belt idler pulley (2) and bolt. Installation Procedure 1. Install the drive belt idler pulley (2) and bolt to the generator bracket. Snug the bolt finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the drive belt idler pulley bolt (1). Page 6888 Page 8304 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 18567 Seat Bladder: Diagrams Component Connector End Views Seat Lumbar Switch - Driver (AN3) Seat Lumbar Switch - Passenger (AN3) Page 200 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 4390 Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement (With ZW9 Cab Chassis) Exhaust Seal Replacement (With ZW9 Cab Chassis) Removal Procedure 1. Remove the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (With Cab Chassis) (See: Catalytic Converter/Service and Repair) . 2. Remove the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement) . 3. Remove and discard the appropriate exhaust seal (1) or gasket (2). Installation Procedure 1. Install the NEW appropriate exhaust seal (1) or gasket (2). Page 7641 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 2727 Page 14052 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 9405 10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 11. Scribe an alignment line between the pinion shaft and the pinion yoke. 12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J 8614-01 . Page 14544 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Page 18442 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 11144 7. Inspect the master cylinder seal (1) for damage and replace, if necessary. 8. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 9. Remove the brake pushrod retainer bolt (1), if equipped. Page 3089 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 377 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Diagrams Discharge Air Temperature Sensor / Switch: Diagrams Component Connector End Views Inside Air Temperature Sensor (CJ2) Page 4281 8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge. 9. Position and align the marks on the upper intermediate steering shaft and the steering column. 10. Install the upper intermediate steering shaft (3) to the steering column. 11. Install the steering shaft coupling bolt (2) and nut (1) to the upper intermediate steering shaft. Tighten the bolt/nut to 50 Nm (37 lb ft). 12. Install the spark plug wires to the spark plugs. 13. Install the spark plug wires to the ignition coils. 14. Inspect the spark plug wires for proper installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 15. Fully raise and support the vehicle. Page 9658 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 20134 Page 20118 Page 20347 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 3551 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 11693 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18297 1. Position the front of the sunshade (3) to the rear of the sunroof frame (2). 2. Install the retaining tabs of the sunshade into the left and right sides of the track slots in the sunroof frame. 3. Slide the sunshade forward while simultaneously inserting the rear retaining tabs into the track slot 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. 5. Install the left and right sunroof housing drain gutters (1) to the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 7. Install the water trough to the sunroof from the top of the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the screws (1) that retain the water trough to the sunroof frame. Tighten the screws to 1 Nm (9 lb in). 9. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Sunroof Track Timing/Synchronization (Extended Cab) Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Extended Cab) Sunroof Track Timing/Synchronization (Extended Cab) Removal Procedure 1. Place the module in the full open position. 2. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 3. Disconnect the electrical connector from the motor/actuator. 4. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . 5. Push the window guides rearward on the track until the guides are positioned against the rear hard stop. Installation Procedure 1. Install the motor/actuator . Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . 2. Connect the electrical connector to the motor/actuator. 3. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 4. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Programming and Relearning) . 5. Verify the operation of the sunroof. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 20395 Turn Signal Switch: Diagrams Component Connector End Views Multifunction Switch - I/P (Except MEX) Turn Signal/Multifunction Switch X1 Page 7009 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Service and Repair Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement (1500) Page 20980 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 7239 Page 10745 15. Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting. 16. Connect the EBCM electrical connector. 17. Connect the electronic brake control position sensor electrical connector. 18. Tighten the brake modulator manual pressure relief valve (1) to 40 Nm (30 lb ft) . Page 13543 Page 17912 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17860 Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Page 16970 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 4624 Page 3293 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the bolt and tighten to 40 Nm (30 lb ft) . 4. Install the collar to the hoist 5. Install the shaft to the hoist. Page 1411 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Place a suitable drain pan under the oil pan drain plug. 3. Remove the oil pan drain plug (430). 4. Allow the oil pan to drain completely. 5. Re-install the oil pan drain plug until snug. 6. Remove the drain pan from under the vehicle. 7. Disconnect the engine harness electrical connector (1) from the oil level sensor. Page 13064 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 11405 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Place the ignition switch in the OFF position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the antilock brake system (ABS) module splash shield retainer (1). Page 20469 View of the connector when released from the component. View of another type of Micro 64 connector. Page 6526 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 16466 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 18219 Page 11646 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 3468 9. Align the CMP actuator so the timing mark is in the 6 o'clock position. 10. Install the CMP actuator (235) and timing chain (208). Align the hole in the face of the CMP actuator with the locating pin on the front face of the camshaft. 11. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 11844 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 6876 Fuel Pump Relay: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 2749 Fuse Block - I/P X3 Page 13809 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (4.8L, 5.3L, 6.0L and 6.2L) Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Note Correct adjustment cannot be achieved if the sunroof window is closed from vent position. 1. Cycle the sunroof window from full open to closed position. Note Do Not remove or lower headliner to access sunroof window screws. 2. Loosen the adjusting screws on the window. 3. Adjust the corners of the front window panel using the following guidelines: * Adjust the front of the sunroof window to 0.0 mm - 1.0 mm (0.0 in - 0.04 in ) below the top surface of the roof panel. * Adjust the rear ceneter line of the sunroof window to 1 mm to 2 mm (0.04 in to 0.08 in ) below the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Tighten the sunroof window adjustment screws. Tighten the sunroof window adjusting screws to 5 Nm (44 lb in). 5. Cycle sunroof window through all positions. 6. Inspect the sunroof window adjustment. Adjust if necessary. Page 5407 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Body Control Module (BCM) X2 Component Locations Multiple Junction Connector: Component Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 574 Page 4115 Radiator Cooling Fan Motor Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ..................................................... 240 Nm (177 lb ft) Page 2671 Page 16997 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 9511 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 3050 Junction Block - Left I/P X11 (except MEX) Page 7931 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 3622 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Tune-up and Engine Performance Checks/Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 7871 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 4614 Drive Motor Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 1769 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 571 Page 17584 Page 19405 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 7118 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14397 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 10087 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 19552 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 18213 Page 1136 Page 7406 24 - Transfer Case Oil Fill Plug 25 - Transfer Case Oil Drain Plug 26 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 27 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 28 - Transfer Case Shift Detent Plunger Plug 29 - Transfer Case Shift Detent Plunger Plug - O-Ring - Seal 30 - Transfer Case Shift Detent Spring 31 - Transfer Case Shift Detent Plunger Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 - Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Insert 12 - Transfer Case Shift Fork Spring Page 11744 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 4871 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12467 Page 15968 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 3084 Page 20420 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 15299 Page 3916 39. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 40. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 41. Remove the EVAP tube and purge solenoid. 42. Remove the throttle body bolts/nuts. 43. Remove the throttle body. 44. Remove and discard the throttle body gasket. Page 2938 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4799 Auxiliary Body Control Module (XBCM) X1 (EXP) Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 7768 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 3461 Install tie wrap (1) to retain the reluctor wheel to the sprocket. The reluctor wheel is mounted to the actuator body with 3 roll pins. Page 12793 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse Block/Diagrams/Connector Views) to locate the electrical center where the relay exists. Note * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 4880 Page 6797 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Page 16708 Speaker - Subwoofer (UQA) Page 14183 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 11847 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11031 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 18894 Seat Heater: Service and Repair Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Page 15336 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 4596 Drive Motor Generator Battery Control Module X3 (HP2) Page 9659 Director, Customer and Relationship Services 09241 Page 13632 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Page 13795 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Page 5725 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 1558 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 11490 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 6684 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 12557 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 19558 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2215 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Page 18210 Memory Seat Module (MSM) X5 (AN3) Page 4657 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Service and Repair Transmission Pressure Test Port: Service and Repair Automatic Transmission Fluid Pressure Test Hole Plug Replacement Page 6309 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 15018 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Engine - Valve Lifter Tick Noise At Start Up Engine Oil: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 5115 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Locations Impact Sensor: Locations Door Component Views Right Rear Door Components (Extended Cab) 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Page 6852 Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 7382 Page 5890 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Backup Lamp Bulb Replacement (Chevrolet) Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement (Chevrolet) Backup Lamp Bulb Replacement (Chevrolet) Page 12679 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Page 5045 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. BW 4485-NR3 - Transfer Case Case Adapter: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Adapter Replacement Page 10376 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 11560 Auxiliary Battery Relay: Connector Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxilary Battery Relay 5 - X122 Page 1299 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) Page 9431 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . Page 16268 Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Page 16308 Object Alarm Sensor - Right Rear Corner (UD7) Object Alarm Sensor - Right Rear Middle (UD7) Page 5572 For vehicles repaired under warranty, use the table above. Disclaimer Page 5362 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor Replacement Page 10828 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Page 13487 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5929 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 18321 Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Crew Cab) Sunroof Track Timing/Synchronization (Crew Cab) Removal Procedure 1. Place the module in the closed/flush position. 2. Remove the sunroof window.Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 3. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 4. Disconnect the electrical connector from the motor/actuator. 5. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . 6. Push the cam assembly (2) forward until the timing hole (3) in the cam is aligned with the timing hole (4) in the lifter arm (1). 7. Insert a pin (1) in the holes to hold the position while installing the drive motor. Note Both mechanisms should now be in the closed position. 8. Repeat this procedure for the opposite side. Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: All Technical Service Bulletins Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17821 Page 20784 9. Remove the cable ends (1) from the window guide (2) at each end of the window. 10. Remove the regulator (1) and cables (2) from the vehicle. Installation Procedure Page 6035 Page 10211 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 15583 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Left Rear Door Components (Extended Cab) Page 10293 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 6764 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 20429 Component Parts Page 8156 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 16347 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 14957 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 14919 Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 7730 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 794 Fuel Pump Relay: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 4343 5. If equipped with a Allison(R) automatic transmission, RPO MW7, remove the exhaust pipe hanger bracket bolt/stud and bracket. 6. If equipped with a 6L90-E automatic transmission, RPO MYD, remove the exhaust pipe hanger bracket bolts and bracket. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. If equipped with a 6L90-E automatic transmission, RPO MYD, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft) . Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 4354 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Page 12441 Junction Block - Left I/P X8 (except MEX) Page 14271 11. Disconnect the power steering assist motor electrical connector at the torque sensor. Note Only remove the 2 bolts indicated in the graphic. Under NO circumstances are the power steering assist motor housing bolts to be removed or loosened. If two or more of these bolts are removed or loosened the steering gear will need to be replaced because the steering gear housing to gear lash will be out of specification. 12. Remove the power steering assist motor bolts (1). Note DO NOT remove the power steering assist motor electrical harness from the power steering assist motor. They are serviced as a unit only. 13. Remove the power steering assist motor and electrical harness (2). 14. Remove and ensure the power steering assist motor seal (3) is kept protected while out of the vehicle as it will be needed for reinstallation. Installation Procedure 1. Install any new wiring harness retainers as needed. Page 12850 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 20639 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Page 5267 Page 11401 Page 1572 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 5586 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 2056 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 11583 Battery (+) (Battery Positive Cable) (HP2) Page 9392 1. Using the J 8611-01 - installer , 8.6 inch axle, or the J 7818 - installer , 9.5/9.5LD inch axle (1), and the J 8092 (2), install the outer pinion bearing cup. 2. Using the J 45870 , 8.6 inch axle, or the J 22306 , 9.5/9.5LD inch axle (2), and the J 8092 (1), install the inner pinion bearing cup. 3. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles))Pinion Depth Adjustment (10.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (10.5 Inch Axle)) . Page 1775 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Body - Roof Panel Flutters/Rattle Noise When Doors Close Headliner: Customer Interest Body - Roof Panel Flutters/Rattle Noise When Doors Close TECHNICAL Bulletin No.: 08-08-67-016F Date: January 24, 2011 Subject: Roof Panel Flutters or Rattle Noise from Roof or Headliner when Closing Doors (Apply Foam) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Models Only), Suburban, Tahoe 2010-2011 Chevrolet Equinox 2007-2009 GMC Sierra (Crew Cab Models Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2010-2011 GMC Terrain Supercede: This bulletin is being revised to add the 2011 model year to Equinox/Terrain models. Please discard Corporate Bulletin Number 08-08-67-016E (Section 08 - Body and Accessories). Condition Some customers may comment that the roof panel flutters and/or there is a rattle noise from the roof or headliner when closing one of the side doors or the liftgate. Cause This may be caused by the excessive motion of the roof panel. On initial inspection, you may notice that the roof panel expansion adhesive material has separated between the roof and the roof bow. The concern is seen mostly on the first cross bow. Correction Lower the headliner assembly (it is not usually necessary to remove the headliner from the vehicle) to gain access to the roof bows. Refer to Headlining Trim Panel Replacement in SI. Remove any loose foam from the roof bow or bows. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or equivalent, in a continuous bead the entire length between the roof bow reinforcement and the roof outer panel. Reinstall the headliner. Refer to Headlining Trim Panel Replacement in SI. Parts Information Contact Lord Fusor at 1-877-275-5673 or on the Web at www.lord.com. Warranty Information For vehicles repaired under warranty, use the table. Page 15567 Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99/MEX) Page 19784 Page 19615 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 11882 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 13308 Page 20872 2. Remove the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. Note The underhood fuse block is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 3. Locate the underhood bussed electrical center (UBEC) (2). 4. Remove the UBEC cover (2) and locate the WSW/HTR 60 amp heated windshield washer fuse. 5. Remove the WSW/HTR 60 amp heated windshield washer fuse (3) using pliers. 6. Discard the WSW/HTR 60 amp heated windshield washer fuse (3). 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Install the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Page 12626 X202 Page 12747 Page 9509 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart usingJ 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). Page 8548 7. Remove the auxiliary fluid pump (2). Caution: The auxiliary fluid pump gasket is not re-usable. Use a NEW gasket when replacing or damage may occur. 8. Remove the auxiliary fluid pump gasket (3). Installation Procedure Caution: The auxiliary fluid pump gasket is not re-usable. Use a NEW gasket when replacing or damage may occur. 1. Install the auxiliary fluid pump gasket (3). Caution: Do not damage the case sealing surface when removing or installing the pump and motor assembly. 2. Install the auxiliary fluid pump (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the auxiliary fluid pump bolts (1). Tighten the bolts to 9-13 Nm (80-115 lb in). 4. Install the auxiliary fluid pump wire harness clip nut (3). Tighten the nuts to 9 Nm (80 lb in). 5. Lower the vehicle. 6. Install the auxiliary fluid pump wire harness (6) to the harness retainers (7). Page 7295 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 14994 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. If equipped, remove the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. 6. Remove the blower motor. Installation Procedure 1. Install the blower motor. Page 1934 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Page 14557 8. Remove the upper link mounting bolt (1) and nut (2) from the link (3). 9. Remove the torsion bar support assembly (4). Note The left and right torsion bars are different and are not interchangeable 10. Remove the torsion bar from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the support assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the upper link mounting nut (2) and the bolt (1) in the link (3). Tighten the nut to 95 Nm (70 lb ft). 4. Install the adjustment arm (2) in the support assembly (1). 5. Install the adjuster bolt (3) and the adjustment nut (4). 6. Slide the torsion bar rearward until the torsion bar is fully seated in the adjustment arm. Page 16982 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13490 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 8062 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 12671 Page 7269 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 12996 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 8294 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 3970 10. Remove the crankshaft sprocket key, if required. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft. Page 4581 Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Page 2017 Seat Position Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 14050 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 16699 1 - Rear Window 2 - Speaker -Left Rear 3 - Driver Door Trim 4 - Speaker -Left Front 5 - Speaker -Center I/P (UQA with Y91) 6 - Speaker -Subwoofer (UQA) 7 - Speaker -Right Front 8 - Speaker -Right Rear Passenger Compartment Components - 2 of 2 (Regular Cab) Page 1890 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Transmission 5 Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 X175 (MW7) Page 20631 Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Motor (A48) Page 5218 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel pressure sensor to the fuel line and tighten the sensor to 15 Nm (11 lb ft) . 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 4916 Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 13293 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 5349 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 12329 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 762 Page 4496 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 5559 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 11504 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer . 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Note If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. 1. Verify the following conditions before centering the SIR coil: * The wheels on the vehicle are straight ahead. * The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. * The ignition switch is in the LOCK position. 2. The front of the SIR coil has a centering window (1). To center the SIR coil perform the following steps: 1. Hold the SIR coil with the face up. 2. Rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow (1) and both arrows (2) line up. This is the CENTER position. 4. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If a double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all other leads to the steering column. Page 9282 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Exhaust - Muffler Heat Shield Buzz During Operation Heat Shield: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Page 8211 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 15961 Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Page 1561 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 10064 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Page 9016 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 6203 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. For 1500 series vehicles, remove the oil pan skid plate bolts and skid plate, if equipped. 3. For 2500 series vehicles, loosen the 2 rear oil pan skid plate bolts, remove the 2 front oil pan skid plate bolts and skid plate, if equipped. Page 7988 Page 6220 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 20551 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2622 Fuse Block - Auxiliary X1 (HP2) Page 6324 4. Remove the CMP actuator (235) and timing chain (208). 5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Installation Procedure Page 2169 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Page 2021 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 5740 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13491 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 7173 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Evaporative Emission (EVAP) Hoses/Pipes Replacement Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement Evaporative Emission System Hoses/Pipes Replacement Removal Procedure Note Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the EVAP canister purge pipe from the fuel tank clip (1). 3. Disconnect the EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Page 7929 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 20981 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 18963 Door Lock/Window Switch - Driver X4 (AN3) Page 5265 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 8755 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12309 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring recepticle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Page 11429 Trailer Brake Control Module (JL1 with 31 Series) Page 4056 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 18585 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 16825 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 9044 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13314 Fuse Block - Underhood Bottom View Page 6657 10. Turn the ignition to the OFF position. 11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12. 12. Disconnect the J 35800-A from the fuel rail. 13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 14. Remove the J 37287 , orJ 42964-1 andJ 42964-2 , orJ 42873-1 andJ 42873-2 and reconnect the vehicle fuel feed and return lines. 15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011 (Canadian P/N 88861012) into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel. 17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 18. Road test the vehicle to verify that the customer concern has been corrected. Capacity Specifications Fluid - Differential: Capacity Specifications AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Page 4446 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 18921 Seat Climate Control Module X3 (KB6) Page 9941 Case Adapter: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Adapter Replacement Page 17186 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 20471 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 3007 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 5145 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 6474 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1) and tighten to 9 Nm (80 lb in) . 5. Install the fuel/EVAP line clip nut (2) and tighten the bolt to 20 Nm (15 lb ft) . 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. Page 3637 6. Remove the connector position assurance (CPA) retainer (2). 7. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness. 8. Remove the engine wiring harness (electronic throttle control branch) clip (6) from the ignition coil bracket stud. 9. Reposition the engine wiring harness (electronic throttle control branch) as necessary. 10. Remove the heater inlet hose (2) from the heater hose bracket (3). Page 15953 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) ) . 5. When carrying a seat belt pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14859 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 6117 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 3701 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Working through the wheelhouse opening, install the engine mount to engine bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Using the adjustable jack, lower the engine until the engine mount is sitting flush on the frame. 4. Remove the adjustable jack from the engine block. 5. Install the engine mount to frame bolts (1). Tighten the bolts to 65 Nm (48 lb ft) starting with the middle bolt then either side bolt. 6. Install the A/C compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (Non-HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Bracket Replacement (HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair) . 7. If the vehicle is equipped with 4WD, Install the front drive axle bracket and bolts. Page 13367 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 2322 Page 20354 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Page 5734 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 18887 * High temperature indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated and cooled seat switch. Ventilation Heat and Cool Module 1. Ignition OFF, disconnect the harness connectors at the seat cushion and seat back ventilation heat and cool modules. Note If the resistance is measured with the seat still warm or cool, the resistance values will vary. At 68°F (20°C), the nominal resistance value is 1200 Ω ±5 percent. For warmer or cooler ambient temperatures, refer to the Temperature vs Resistance table below. The delta resistance values between the seat cushion and seat back temperature sensors should not be greater than 2000 Ω. 2. Test for 300 Ω - 18 kΩ between the temperature sensor signal circuit terminal 5 and the low reference circuit terminal 8. ‹› If not within the specified range, replace the ventilation heat and cool module. Note The test leads must be connected in the correct polarity, otherwise lower out of range values will appear. Use the Positive Lead for the COOL control circuit and the Negative Lead for the HEAT control circuit. If the resistance is measured with the seat still warm or cool, the resistance values will vary even if the system was powered up for just a few seconds. The TED must be allowed to stabilize to room temperature prior to a measurement. The conditions listed below will change the resistance to out of range values: * The test leads are incorrectly connected. * Air blowing across the TED * Measuring the resistance at other than room temperature of 70°F * Holding the TED portion of the heated and cool ventilation module in your hand In warmer or cooler climates where room temperature conditions of 70°F (21°C) may be unattainable, resistance values may read above the specified range. Use a heat gun or a blower to warm or cool the TED while measuring the resistance. The resistance values should slowly lower toward the specified range. 3. Test for 0.9 - 10.0 Ω between the heat control circuit terminal 1 and the cool control circuit terminal 3. ‹› If not within the specified range, replace the ventilation heat and cool module. Note The test leads must be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the control circuit and the Negative Lead for the ground circuit. 4. Test for 6 k - 9 kΩ between blower motor control circuit terminal 2 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Note The test leads need to be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the speed control circuit and the Negative Lead for the ground circuit. 5. Test for 290 k - 420 kΩ between blower motor speed control circuit terminal 7 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Page 7948 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 11459 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Page 5845 Page 8690 Seals and Gaskets: Service and Repair Output Shaft Seal Replacement Output Shaft Seal Replacement Page 3516 1. Compress the timing chain tensioner guide and install the EN 46330 . Note * Properly locate the CMP actuator on the locating pin of the camshaft. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. * DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly. 2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Page 18097 Memory Seat Module (MSM) X4 (AN3) Page 18970 Page 747 Engine Control Module (ECM) X2 (Diesel) Page 8076 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 5305 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 5192 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 12180 Page 14454 Tie Rod: Service and Repair Steering Linkage (Non-Rack & Pinion) Steering Linkage Inner Tie Rod Replacement Special Tools J 34028 Inner Tie Rod Wrench Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 2. Remove the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Inner Tie Rod Replacement) . 3. Remove the steering linkage inner tie rod (1) from the relay rod using wrenchJ 34028 (2). Installation Procedure 1. Remove all traces of oil, grease, or other contaminants. 2. Clean the threads of the steering linkage inner tie rod with denatured alcohol or the equivalent and allow to dry. 3. Apply red LOCTITE(TM) threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the steering linkage inner tie rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the steering linkage inner tie rod (1) to the relay rod using wrenchJ 34028 (2) and tighten to 100 Nm (74 lb ft) . 5. Install the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Inner Tie Rod Replacement) . 6. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 7. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Page 8405 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Front Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Shock Absorber, Shock Absorber Component, or Spring Replacement Shock, Shock Component, and/or Spring Replacement Special Tools CH-48845 Spring Compressor Removal Procedure Warning Use only the CH-48845 Spring Compressor when servicing suspension components on this vehicle. Other tools may not be strong enough for the springs on this vehicle and you could be injured if you do not use Special Tool CH-48845. Failure to do so could result in serious personal injury. Note Use only hand tools to perform the following service procedure. 1. Install the front shock absorber assembly in theCH-48845 . Note: For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 2. Position the shock absorber (2) in the upper retaining bracket of theCH-48845 (1) so the shock absorber will be centered. Page 10061 Page 20519 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 11586 5. Remove the auxiliary battery positive cable connector (1) from the underhood bussed electrical center (UBEC). 6. Remove the mega fuse cover (3). 7. Disconnect the auxiliary battery positive cable electrical connector (2) from the engine wiring harness connector. 8. Remove the relay (1) clip from the stud on the front of dash. Page 8714 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 13462 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7242 2-3 Shift Solenoid (SS) Valve (M30) Shift Solenoid (SS) Valve 1 (MW7) Page 6397 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 1836 Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (3). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (6). Page 20462 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 15949 Seat Belt Tensioner: Diagrams Component Connector End Views Seat Belt Pretensioner - Driver Seat Belt Pretensioner - Passenger Page 3117 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 2248 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft) . 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 12664 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (D07 with UQ3 or AZ3/HP2) Page 3779 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement) . 2. If equipped with regular production option (RPO) L76 (6.0L) engine, perform the following. 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . Locations Auxiliary Water Pump Relay: Locations Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 779 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 13789 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 1808 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 20523 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 16981 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 18932 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 3834 8. Remove the oil level sensor from the oil pan. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the oil level sensor to the oil pan. Tighten the sensor to 20 Nm (15 lb ft). 2. Connect the engine harness electrical connector (1) to the oil level sensor. Page 5350 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 10333 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5881 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (6.0L with ZW9) Page 11743 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 18853 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 1402 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 9017 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 13447 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 20517 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Diagrams Safety Disconnect Impact Sensor: Diagrams Component Connector End Views High Voltage Circuit Impact Detection Sensor (HP2) Page 20105 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 14942 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 1146 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7128 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 3017 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 9245 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Page 2115 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 7131 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 10274 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 6794 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 4266 Generator Control Module Coolant Pump - Left (HP2) Page 2235 Alignment: Description and Operation Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Page 7493 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 3123 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Locations Hazard Warning Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 5579 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 10478 10 - Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4) 11 - Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plate (Qty: 7) 12 - Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plate (Qty: 8) 13 - Transfer Case Four Wheel Drive Clutch Hub 14 Transfer Case Four Wheel Drive Clutch Shim 15 - Transfer Case Two/Four Wheel Drive Clutch Retaining Ring 16 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Front 17 - Transfer Case Four Wheel Drive Clutch Housing Retaining Ring 18 - Transfer Case Four Wheel Drive Clutch Housing Page 8240 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 15528 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 11317 Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement Power Brake Booster Replacement (Non-Adjustable Pedals) Page 5640 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 11896 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12759 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 495 Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 12276 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 13552 Page 6168 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 10075 Input Shaft Seal Replacement Input Shaft Seal Replacement Page 13974 For vehicles repaired under warranty, use the table. Disclaimer Page 4548 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in ). Note Only use pre-mixed DEX-COOL(R) on the coolant pipe O-ring to aid in tube installation. 4. Lubricate the new seals (6, 9) with pre-mixed DEX-COOL(R). 5. Install new seals (6, 9) onto the drive motor generator power inverter coolant pipes (5, 8). 6. Install the coolant pipes (5, 8) to the PIM assembly with bolts (4, 7). Tighten the fasteners to 5 Nm (44 lb in) . 7. Rotate the drive motor generator control module assembly onto the APM. 8. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 9. Plug the remaining coolant pipe with the GE-48494 - adapter kit plug and clamp (1). Page 19779 Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM replacement, setup, and programming Page 11704 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 2940 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6847 Page 1138 Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Page 19497 Air Bag Deactivation Indicator: Diagrams Component Connector End Views Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 Except MEX) Page 14933 Instrument Panel Center Air Outlet Replacement (With RPO SLT) Instrument Panel Center Air Outlet Replacement (With RPO SLT) Page 449 Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 9924 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 8758 Page 4204 Page 5645 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 5405 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 10525 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 2494 Disclaimer Page 12360 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 18377 Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 3. Ensure that the sunroof does not have any air or waterleaks. Page 9931 Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF/NQH) Page 11134 8. Connect the brake master cylinder primary brake pipe fitting (1). Tighten the fitting to 30 Nm (22 lb ft). 9. Connect the brake master cylinder reservoir return hose quick connect (1). 10. Connect the brake master cylinder reservoir supply hose quick connect (2). 11. Connect the brake fluid level sensor electrical connector. 12. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Procedures/Master Cylinder Replacement (Vacuum Boost)) . 13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . Master Cylinder Replacement (ABS) Page 20875 2009 Chevrolet Traverse 2007-2009 GMC Acadia 2007-2009 Saturn OUTLOOK 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood bussed electrical center (UBEC) is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Note Remove the two relays next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in Page 12739 Page 2437 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. DRIVE MOTOR/GENERATOR CONTROL MODULE (DMCM) COOLING SYSTEM Always use the pre-mixed 50/50 mixture of de-ionized water and DEX-COOL (silicate-free) coolant. Page 9088 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 4598 Drive Motor Generator Battery Control Module X5 (HP2) Page 1203 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 11907 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 2213 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 10904 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 6770 See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 29. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 30. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 13512 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit MP 1222/1225/1226-NQG - Transfer Case Transfer Case Actuator: Locations MP 1222/1225/1226-NQG - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 2951 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15261 Page 8847 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 2831 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Page 6235 Locations Rain Sensor: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 9749 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 373 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 16306 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp - Right 6 - Object Alarm Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Alarm Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Alarm Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Alarm Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left Page 68 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4751 Drive Motor Generator Battery Control Module X5 (HP2) Page 13892 Page 1151 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Page 11509 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 17746 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 3322 Disclaimer Page 15184 7. Remove the evaporator core (1) from the upper HVAC module assembly (2). Installation Procedure Note If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities (Non-HP2) () . 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1) 3. Install the evaporator cowl gasket to the evaporator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the screws to the HVAC module assembly. Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair) . Page 17130 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 9521 7. Using the J 2222-C - wrench , and loosen the adjusting nut. 8. Remove the adjusting nut. Note If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 11. Using a suitable seal removal tool, remove the oil seal from the wheel hub. Page 8627 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 7166 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 19522 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4915 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Page 5016 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 10207 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 20353 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 16711 Speaker: Service and Repair Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Locations Fuel Pressure Sensor/Switch: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 20456 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Capacity Specifications Coolant: Capacity Specifications Engine Cooling System ....................................................................................................................... .............................................. 17.2 quarts (16.3 liters) Drive Motor Generator Control Module Cooling System ..................................................................................................................... 2.5 quarts (2.4 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 344 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 12357 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 6611 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Front Seat Heater Control Module Replacement Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Front Seat Heater Control Module Replacement 09-08-64-017A - END OF INFORMATION NEED Power Window Control Module: Technical Service Bulletins 09-08-64-017A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-64-017A Date: October 29, 2009 Subject: EI09133 - Power Windows Intermittently Inoperative (Engineering Information Closed) Models: 2009 Chevrolet Silverado 2009 GMC Sierra With RPO A31 Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-64-017 (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 11552 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in) . 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in) . 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . Page 8460 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 1829 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. If equipped with 2 wheel drive (2WD) perform the following steps, if equipped with 4 wheel drive (4WD) proceed to step 5. 3. Remove the connector position assurance (CPA) retainer (2). 4. Disconnect the HO2S electrical connector (3) from the engine wiring harness electrical connector (5). 5. Remove the connector position assurance (CPA) retainer (2). 6. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Page 7777 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 6365 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 3626 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service and Repair/Overhaul) . Installation Procedure Note When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Page 12222 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 1441 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 10255 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 16614 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 17080 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 17691 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees . 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in) . 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft) . Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 1403 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 6592 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 16700 1 - Inflatable Restraint Roof Rail Module -Driver (ASF) 2 - Inflatable Restraint Roof Rail Module -Passenger (ASF) 3 - Floor Panel Page 17568 Rear Door Window Regulator: Service and Repair Rear Sliding Window Regulator Replacement Rear Sliding Window Regulator Replacement Removal Procedure Note The new rear sliding window regulator and cables are serviced as an assembly. 1. Cycle the rear sliding window to the halfway position. 2. Remove the rear lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . Note Use a suitable tool to lift upward on the rear sliding window stops (1) to remove. 3. Remove the rear sliding window stops (1). Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor Removal Procedure 1. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair) . 2. Disconnect the spark plug wire at the spark plug. * Twist each plug wire boot 1/2 turn. * Pull only on the boot in order to remove the wire from the spark plug. Note Page 9385 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement) . 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft) . 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 16. Lower the vehicle. Page 8726 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Page 13172 Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (4.3L) Page 7746 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 7593 Page 18838 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 1540 Fuel Gauge Sender: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 5677 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 7811 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 6660 10. Remove the CPA retainer. 11. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 12. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control. 13. Disconnect the engine wiring harness electrical connectors (5) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 14. Remove the engine wiring harness clip (4) from the ignition coil bracket stud. Note The auxiliary heater water pump hose and the surge tank outlet hose do not need to be removed from the bracket in order to reposition the bracket. 15. Remove the heater hose bracket nut (2) and bracket (1). Reposition the bracket out of the way. Hoses shown removed for clarity. Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 5517 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 6478 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 3536 1. Apply a 5 mm (0.2 in) bead of sealant, 20 mm (0.8 in) to the 2 joints (a) at the rear of the block/pan. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . 2. Inspect the rear oil gallery plug for proper installation. Installation Procedure - Cover with Seal 1. Install the J 41479-2A cone and bolts onto the rear of the crankshaft. Page 19825 Fuel Pump and Sender Assembly - Rear (LY6 without NQZ Except MEX) Page 15290 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Page 883 Page 19539 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 12508 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure Navigation Radio - Weak Or No GPS Signal Information Global Positioning System: All Technical Service Bulletins Navigation Radio - Weak Or No GPS Signal Information INFORMATION Bulletin No.: 08-08-44-027 Date: August 12, 2008 Subject: Information on Navigation Radios that Have a Weak or No GPS Signal Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models with Navigation Radios Some customers may comment on intermittent or no Global Positioning System (GPS) signal reception on the Navigation radio. The GPS signal reception icon on the map screen may have a red line through it. This condition may be caused by aftermarket electronic devices such as radar detectors, cell phones, and MP3 players that may interfere with the GPS signal reception. Aftermarket window tinting or clear UV film applied to the windshield may also reduce the GPS signal reception and cause the Navigation radio to function incorrectly. Recommendations Educate the customer on the GPS antenna location and the need to keep electronic devices away from it. The GPS antenna is located in the upper center of the Instrument Panel. Instruct the customer to move electronic devices away from the GPS antenna. It may also be necessary to remove aftermarket films and tinting from the windshield. Do not replace a Navigation radio that seems to have poor GPS signal reception without considering these possible causes of the concern. Refer to the No Global Positioning System (GPS) Reception diagnostic procedure in SI for more information. Disclaimer Page 18053 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (except AN3/DL3) Page 11879 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 20161 License Plate Lamp: Service and Repair Rear License Plate Lamp Bulb Replacement Rear License Plate Lamp Bulb Replacement Page 10057 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 20003 Page 14563 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 13038 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1647 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 13336 Fuse Block - Mobile Radio (9L4) Page 13786 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Locations Audible Warning Device Control Module: Locations Instrument Panel/Center Console Component Views Inside the I/P Components (UL5) 1 - Chime Module Page 13370 Junction Block - Rear Lamps X4 Page 13171 Page 9370 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear drive axle. * Use the proper fluid, refer toApproximate Fluid Capacities . * For the proper capacity, refer toFluid and Lubricant Recommendations . 3. Install the fill plug and tighten to 33 Nm (24 lb ft) . 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure Page 12498 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 2752 Page 10291 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 5728 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 13170 Page 2958 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 2016 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 13673 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 13133 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 4736 Generator Control Module Temperature Sensor (HP2) Page 9020 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 7011 Page 11866 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 12226 Junction Block - Left I/P X1 (except MEX) Page 19637 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 18350 Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Suspension - Multiple Noises From Front Of Vehicle Suspension Travel Bumper: Customer Interest Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Page 2762 Fuse Block - Underhood X1 Page 19364 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 1492 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Locations Radiator Cooling Fan Motor: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Page 13343 Page 8303 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 3. Remove the connector position assurance (CPA) retainer (4). 4. Disconnect the engine wiring harness electrical connector (7) from the HO2S. 5. Remove the HO2S electrical connector clip (6) from the fuel line clip. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 11062 Page 17770 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 11085 4. Remove the ABS module splash shield bolts (1). 5. Remove the ABS module splash shield (1). 6. Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake pipe fittings. Page 2934 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4941 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 9922 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case Two/Four Wheel Drive Actuator Cam 15 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 16 - Transfer Case High/Low Shift Fork 17 - Transfer Case High/Low Shift Fork Pads 18 - Transfer Case High/Low Shift Fork Spring Assembly 19 - Transfer Case High/Low Shift Fork Pin 20 Transfer Case Control Actuator Shaft 21 - Transfer Case Rear Output Shaft 22 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 23 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 24 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 25 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring 26 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring 27 - Transfer Case Front Output Shaft Drive Chain Assembly 28 - Transfer Case Front Output Shaft Drive Sprocket 29 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 30 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 31 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 32 Transfer Case Oil Pump Assembly 33 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 34 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 35 - Transfer Case Rear Output Shaft Rear Bearing Assembly 36 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 37 - Transfer Case Oil Pump Suction Pipe Seal 38 - Transfer Case Oil Pump Suction Pipe 39 - Transfer Case Front Output Shaft Rear Bearing Assembly 40 - Transfer Case Front Output Shaft Driven Sprocket Spacer 41 - Transfer Case Front Output Shaft Driven Sprocket 42 - Transfer Case Front Output Shaft Hole Plug 43 - Transfer Case Front Output Shaft 44 Transfer Case Front Output Shaft Front Bearing Assembly Driver Information Display Switch Replacement (without RPO SLT) Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Page 4013 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Replacement Camshaft Position Actuator Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . 2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234). Page 551 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 20901 6. Cut the five-wire connector from the windshield washer solvent heater assembly. Vary the length of the five wires on the connector. 7. Discard the windshield washer solvent heater assembly and, if install in recall 08048, the jumper harness with inline fuse. 8. Wrap the large connector with two wires in electrical tape. 9. Wrap the red and green wires on the small connector separately. 10. Wrap the five wires on the small connector with electrical tape. Wheels/Tires - Module Programming For 20/22 Inch Wheels PROM - Programmable Read Only Memory: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 13035 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 4089 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Page 13347 Junction Block - Left I/P X3 (except MEX) Service and Repair Wiper Arm: Service and Repair Windshield Wiper Arm Replacement (LD) Page 9892 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 1619 Turn Signal Switch: Diagrams Component Connector End Views Multifunction Switch - I/P (Except MEX) Turn Signal/Multifunction Switch X1 Page 19475 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Page 16249 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 5654 Information Bus: Locations Instrument Panel/Center Console Component Views Serial Data Gateway (SDG) Module (HP2) 1 - Serial Data Gateway (SDG) Module Page 6486 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1) and tighten to 9 Nm (80 lb in) . 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft) . 6. Remove the caps from the fuel and EVAP lines. 7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line. Page 6669 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 27. Install the engine wiring harness clip (4) to the ignition coil bracket stud. 28. Connect the engine wiring harness electrical connector (1) to the MAP sensor (4). 29. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid (3). 30. Install the engine wiring harness bracket nut (1). Tighten the nut to 5 Nm (44 lb in). 31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 18467 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Component Views Page 10413 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 4531 Accessory DC Power Control Module (APM) Location The APM is affixed to and located underneath the PIM. It is fastened to the PIM with external mounting fasteners and 2 internal high voltage circuit connection fasteners. The APM shares a coolant passage with the PIM and as such is gasketed to the PIM. Operating Functions The APM is the device which converts high voltage (300V) direct current (DC) to low voltage (12V) DC for accessory electrical operation and to charge the 12 volt accessory battery. The APM also converts HV DC to intermediate (42V) DC to supply the electric power steering system with voltage. The APM is capable of supplying up to 175 Amps of 12 volt DC and up to 50 Amps of 42 volt DC. In Jump Assist mode the APM converts 12 volt DC to HV DC to charge the high voltage hybrid batteries. The APM is capable of supplying up to 2.7 Amps at 290 volts DC on the high voltage circuit when operating in Jump Assist. An external 12V DC battery charger is required during the Jump Assist mode because the APM and vehicle controllers may draw as much as 80 Amps of current from the vehicles 12 volt DC system. Communication and Hosted Diagnostics The APM has internal diagnostic tests that run at both power-up and during operation. All DTCs from the APM are reported to and hosted by the HPCM. The APM communicates directly only with the HPCM and only on the high speed hybrid GMLAN communication circuit. Circuit Inputs Inputs supported by the APM include the high voltage and 12 volt circuits. The APM also monitors various internal components for current, voltage and temperature. The APM is also connected to the high speed hybrid GMLAN communication circuit. An individual 12 volt discrete circuit powers ON the APM. The APM will not begin conversion of voltage however, until the appropriate GMLAN enable signal is communicated to it by the HPCM. Circuit Outputs The only outputs supported by the APM are the 12 volt and 42 volt conversion during normal vehicle operation and high voltage conversion during Jump Assist. Page 12582 1 - X700 2 - Door Frame Left Rear Door Harness Routing (Crew Cab) Page 13823 X150 Inline Harness Connector End Views X150 Engine Harness to I/P Harness (HP2) Page 18367 Disclaimer Page 6998 5. Connect the ignition coil wiring harness electrical connector (1) to the ignition coil. 6. If replacing one of the rear 2 ignitions coils on the right side perform steps 7 through 16, otherwise proceed to step 17. 7. Install the engine bracket (3) to the ignition coil bracket stud and install nut (1). Tighten the nut to 9 Nm (80 lb in). 8. Raise the vehicle half way. 9. Working through the wheel opening, install the engine bracket bolts (2). Tighten the bolts to 50 Nm (37 lb ft). Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 12753 X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 18474 Memory Seat Module (MSM) X4 (AN3) Page 7130 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 6678 3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting. 6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction. Page 10248 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 20446 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 4298 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12645 X278 Inline Harness Connector End Views X278 Instrument Panel harness to Body harness (MEX/A52) Page 7937 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8279 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 11993 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 18952 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Page 8236 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 12591 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Page 7945 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 17236 Body Control Module (BCM) X5 Page 9347 27 - Differential Pinion Thrust Washer 28 - Differential Pinion Gear 29 - Differential Side Gear Washer 30 - Differential Side Gear 31 - Output Shaft Snap Ring 32 - Differential Pinion Gear 33 - Differential Pinion Gear Thrust Washer 34 - Differential Side Gear 35 - Differential Side Gear Washer 36 - Differential Cross Pin 37 - Ring Gear Bolt 38 - Output Shaft Bearing Assembly 39 8-Point Lock Ring 40 - Sleeve and Insert Assembly 41 - Differential Side Bearing Assembly 42 Carrier Gasket 43 - Carrier Cover 44 - Tube Locator Pin 45 - Inner Output Shaft Thrust Washer 46 - Inner Output Shaft Bearing Assembly 47 - Inner Output Shaft 48 - Carrier Bolt 49 - Shifter Spring 50 - Shifter Fork 51 - Shifter Fork Rod 52 - Tube Bolt 53 - Shift Actuator Assembly 54 - Output Shaft Seal Assembly 55 - Output Shaft Bearing Assembly 56 - Tube 57 - Tube Gasket 58 - Output Shaft Locator Thrust Washer 59 - Output Shaft Thrust Washer 60 - Output Shaft Snap Ring 61 Shifter Sleeve Page 3702 Tighten the bolts to 90 Nm (67 lb ft). 8. If the vehicle is equipped with 4WD, Install the front drive axle. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD), See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement 9. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L, and 6.2L) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (6.6L) (See: Exhaust System/Exhaust Manifold/Service and Repair )Exhaust Manifold Replacement - Right Side (4.3L) (See: Exhaust System/Exhaust Manifold/Service and Repair) . Page 7231 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 19360 Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 17631 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Hybrid 2 Mode) Endgate Emblem/Nameplate Replacement (HYBRID 2 Mode) Page 3504 6. Remove the pushrods. 7. Clean and inspect the rocker arms and pushrods, if required. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection (See: Service and Repair/Overhaul) . Installation Procedure Note When reusing the valve train components, always install the components to the original location and position. Valve lash is net build, no valve adjustment is required. 1. Lubricate the rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the rocker arm bolts with clean engine oil. Lubricate the flange or washer surface of the bolt that will contact the rocker arm. 3. Install the rocker arm pivot support. Note Make sure that the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Page 13055 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 6027 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 13275 Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Page 9397 11. Using a brass drift and a hammer, remove the pinion gear pilot bearing. Installation Procedure 1. Position the drive pinion pilot gear bearing (1) in the differential housing (2). Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 3. Remove the connector position assurance (CPA) retainer (4). 4. Disconnect the engine wiring harness electrical connector (7) from the HO2S. 5. Remove the HO2S electrical connector clip (6) from the fuel line clip. Description and Operation Camshaft: Description and Operation Camshaft Position Actuator and Solenoid Valve Description Camshaft The camshaft is designed to provide a lubrication path for pressurized engine oil to flow to the camshaft position (CMP) actuator. Pressurized engine oil enters the camshaft at bearing journal location number 2. Oil travels through the camshaft, out the front, and into the CMP actuator solenoid valve. CMP Actuator Solenoid Valve The CMP actuator solenoid valve consists of a housing, spool valve (1), spool return spring (2), oil filter (3), inlet check ball return spring (4), and inlet check ball (5). Pressurized engine oil enters the valve and travels through the filter to the spool. Spool position is controlled by the CMP magnet and engine control module (ECM). When the spool is moved to the proper position, oil flow is directed through the valve and into the CMP actuator assembly. The CMP solenoid valve is a torque-to-yield design and should be replaced each time it is removed. CMP Actuator Magnet Page 3787 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Refer to Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection) . Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install a new retaining ring into each quick connector fitting. Page 10913 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 7950 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 13615 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Camshaft Position Actuator Magnet Replacement Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Magnet Replacement Camshaft Position Actuator Magnet Replacement Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement. 2. Disconnect the engine harness electrical connector from the camshaft position (CMP) actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note The gasket surface should be free of oil or other foreign material during assembly. Page 5721 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 958 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 4725 Drive Motor Generator Battery Control Module X5 (HP2) Page 3686 3. Tighten the drive belt tensioner bolts. Tighten the bolts to 50 Nm (37 lb ft). 4. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair/Drive Belt Replacement) . Page 7968 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3711 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Tools Required * EN-47971 Oil Pressure Gage Adapter * J 21867 Pressure Gage 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. With the vehicle on a level surface, run the vehicle for a few minutes. Allow adequate drain down time, 2-3 minutes, and measure the oil level. 3. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 4. Run the engine briefly, 10-15 seconds, and verify low or no oil pressure on the vehicle gage or light. 5. Listen for a noisy valve train or a knocking noise. 6. Inspect for the following conditions: * Oil diluted by water or glycol antifreeze Refer to Coolant in Engine Oil (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Coolant in Engine Oil) . * Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal 7. Remove the oil filter and install the EN-47971 (1). 8. Install the J 21867 (2), or equivalent to the EN-47971 (1). 9. Run the engine and measure the engine oil pressure. 10. Compare the readings to Engine Mechanical Specifications (See: Specifications/Service Limit & General Specifications/Engine Mechanical Specifications) . 11. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: * Oil pump worn or dirty Refer to Oil Pump Cleaning and Inspection (See: Service and Repair/Overhaul) . * Oil pump-to-engine block bolts loose Refer to Oil Pump, Screen and Crankshaft Oil Deflector Installation (See: Service and Repair/Overhaul) . * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump * Excessive bearing clearance * Cracked, porous, or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Plug Installation (See: Service and Repair/Overhaul) . * Improper operation of the active fuel management oil pressure relief valve Page 13390 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components Page 10768 Page 20542 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 17759 Disclaimer Page 8324 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Torque Converter Clutch (TCC) Solenoid Valve (M30) Service and Repair Child Seat Tether Attachment: Service and Repair Child Seat Restraint System Belt Bracket Replacement (Ext Cab/Crew Cab) Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 12499 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Page 5499 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 5666 MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Locations Fuel Pressure Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 1645 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 5819 ‹› If not the specified value, test the serial data circuit for a short to ground, refer to Testing the Serial Data Circuits for a Short to ground. 6. Disconnect the harness connector at the JX 221 splice pack. 7. Test for less than 2 ohm between the serial data circuit terminal 1 and the JX 221 splice pack terminal D. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuits test normal, replace the splice pack. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 1 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Test for infinite resistance between the DLC serial data circuit terminal 1 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to ground. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. If equipped with a JX 339 splice pack, ignition ON, verify the scan tool communicates with one or more control modules connected to the JX 339 splice pack. ‹› If all control modules on the JX 339 spice pack do not communicate, test the serial data circuit between the JX 221 and JX 339 splice packs for an open/high resistance. If the circuit tests normal, test each splice pack for an open/high resistance. 2. Ignition OFF, disconnect one of the harness connectors listed below: * JX 221 if the control modules not communicating are connected to the JX 221 splice pack * JX 223 if the control modules not communicating are connected to the JX 223 splice pack, if equipped * JX 339 if the control modules not communicating are connected to the JX 339 splice pack 3. Install a 3A fused jumper wire between the disconnected splice pack connector terminal listed below and a low speed GMLAN serial data circuit that is not communicating: * JX 221 terminal D * JX 223 terminal A * JX 339 terminal A 4. Ignition ON, verify the scan tool communicates with the control modules connected to the low speed GMLAN serial data circuit. ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Repair Instructions Perform theDiagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 1353 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (Except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4/HP2) Page 4999 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 13730 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 4542 9. Remove the caps (3, 6) from the drive motor generator power inverter coolant pipes. 10. Connect the drive motor generator power inverter module (PIM) cooling inlet and outlet hoses (4, 5). 11. Install the shield circuit harness (1) and terminal fastener (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 12. Install the PIM 3 phase cables (3, 5) into the PIM distribution box with new seals (6). 13. Install the PIM 3 phase cable mounting fasteners (2, 4). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 14. Install the PIM 3 phase cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . Page 15617 Page 5894 3. Connect the engine wiring harness electrical connector (7) to the HO2S. 4. Install the engine wiring harness electrical connector clip (6) to the fuel line clip. 5. Install the CPA retainer (4). 6. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Lower the vehicle. Page 520 Page 13315 Fuse Block - Underhood X1 JX221 Branching Point: Diagrams JX221 Splice Pack Connector End Views JX221 A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 8818 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . Note Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Page 7 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 19607 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 15604 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Page 18335 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the water gutter screws (1). Tighten the screws to 2 Nm (18 lb in). 5. Install the sunroof module. 6. Open the sunroof window to the fully open position. 7. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair )Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair) . 8. Remove the tape from around the perimeter of the sunroof window. 9. Verify that the sunroof is operating properly. Sunroof Housing Drain Gutter Replacement (Crew Cab) Sunroof Housing Drain Gutter Replacement (Crew Cab) Page 3057 Page 4904 3. Position the engine wiring harness electrical connectors and engage the retainers securing the connectors (2) to the ECM (1). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 7797 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10868 Brake Pad: Testing and Inspection Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. 2. If replacement is necessary, always replace disc brake pads in axle sets. 3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads. 4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. 5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. 6. Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. 7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. 8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. 9. Replace the disc brake pads if any have separated from the mounting plates. 10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to theMaster Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 4750 Drive Motor Generator Battery Control Module X4 (HP2) Page 19435 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 13778 X305 Body Harness to Passenger Seat Harness (Except AN3/MEX) X309 Page 19807 Audible Warning Device Control Module: Diagrams Component Connector End Views Chime Module (UL5) Page 4283 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair) . 2. Fully raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar. 4. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Front Seat Heater Control Module Replacement Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Front Seat Heater Control Module Replacement Service and Repair Spoiler: Service and Repair Rear Spoiler Replacement (901/902) Page 584 Page 13257 Page 7232 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 383 Trailer Brake Control Relay (JL1) Trailer Brake Control Switch (JL1) Page 8486 6. Remove the control solenoid valve heat sink bolts (1) from the control solenoid valve and transmission control module (TCM) assembly. 7. Remove the wire harness retainer (2). 8. Remove the control valve body bolts (3) from the control solenoid valve and TCM assembly. 9. Remove the control solenoid valve and TCM assembly (4). Caution: Use care when handling the control valve body assembly. If dropped, damage to the control solenoid valve body assembly internal components, including the transmission control module (TCM), may result. Caution: Discard the channel plate. Replace with a NEW channel plate. Reusing an old channel plate may cause damage to the control solenoid valve assembly. Note Use care when removing the channel plate assembly. However, if a retaining tab is broken or missing, DO NOT replace the control solenoid valve assembly. The channel plate assembly can still be adequately aligned. 10. Remove the control valve channel plate spacer plate gasket (1). 11. Remove the transmission wiring harness assembly (2). Installation Procedure Page 20873 Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer or record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2006-2007 HUMMER H2 1. Open the hood and disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver's side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Bock in the Owner's Manual for fuse information. 2. Locate the under-hood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer Mega fuse. 4. Remove the two nuts (1) for the Mega fuse (2). Refer to the picture. 5. Remove the 60 amp heated windshield washer Mega fuse. 6. Discard the 60 amp heated windshield washer Mega fuse. 7. Install the two nuts back into the two studs. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. Page 8986 Locations Battery Temperature Sensor/Switch: Locations Generator Battery Temperature Sensor Location Page 9129 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 3088 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 11191 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 5281 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis (W/O FPCM) Fuel System Diagnosis (w/o FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Fuel Pressure Gage * J 37287 Fuel Line Shut-Off Adapters Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer toFuel System Diagnosis (w/o FPCM) Fuel System Diagnosis (w/FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 2. Ignition OFF, all accessories OFF, install theCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 3. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: Page 8811 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5367 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 13326 Fuse Block - Underhood X6 Page 5188 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 17063 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 12398 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 8982 Switches and Relays Page 3456 The CMP actuator magnet (752) is located in the engine front cover and is sealed by a gasket (753). The CMP actuator magnet is controlled by a 12-volt 150 Hz pulse width 0-100 percent duty cycle signal from the ECM. When energized, the solenoid uses electromagnetic force on the magnet pintle to position the spool valve of the CMP solenoid valve. CMP Actuator The CMP actuator is a vane type design that hydraulically changes angle or timing of the camshaft relative to crankshaft position. The CMP actuator allows earlier or later intake and exhaust valve opening during the 4-stroke engine cycle. The CMP actuator cannot vary the duration of valve opening or valve lift. The CMP actuator is to be serviced as an assembly. For system operation, refer to Camshaft Actuator System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Camshaft Actuator System) . The CMP actuator consists of the CMP reluctor wheel (1), wheel retaining pins (2), return spring (3), front cover (4), park position pin (5), park position pin spring (6), vanes and vane springs (7), rotor (8), housing with chain sprocket (9), sealing cover/thrust plate (10), and bolts (11). CMP System Operation Page 5037 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 10214 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 5306 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 18733 Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Special Tools * J 22833 Input/Countershaft Race Installer * J 24433 Pinion Cone & Side Bearing Installer * J 39477 Puller Kit Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 3. Install the J 39477 (1) on the center bearing assembly (2). 4. Position the J 39477 (1) in a vise 5. Using the J 39477 (1), remove the center bearing assembly (2) from the propeller shaft. Installation Procedure OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 8290 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 3486 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2070 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 5231 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 6811 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 10. Remove the fuel tank fill pipe. 11. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Page 2323 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Page 12086 Fuse Block - Underhood X6 Page 7596 Page 20787 1. Align the tabs (2) on the pulley (1) with the notch in the frame (3). 2. Turn the pulley downward, locking the pulley into the frame (3). 6. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame. 7. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place. Page 7989 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Torque Converter Clutch (TCC) Solenoid Valve (M30) Page 19635 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 6113 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 5814 Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Page 422 Page 6721 Page 12909 Disclaimer Page 20833 Page 9193 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric) Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) orRear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair ) 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Page 11289 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Valve Body: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 20114 Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Page 6979 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 4. If the right side spark plug wire(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . Page 9067 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Page 5172 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 12782 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 16581 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 10287 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 9119 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 1194 Door Lock/Window Switch - Driver X7 (AN3/DL3) Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6924 1 - Turbocharger Vane Position Control Solenoid Valve 2 - Glow Plug Control Module (GPCM) 3 Fuel Temperature Sensor 4 - Intake Air Temperature (IAT) Sensor 2 Connector 5 - X128 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Generator - Auxiliary (K76/YF2) 8 - A/C Compressor Clutch (C67/CJ2) 9 - Engine Coolant Temperature (ECT) Sensor 10 - Camshaft Position (CMP) Sensor 11 - X127 12 - Generator 13 - Manifold Absolute Pressure (MAP) Sensor 14 - Intake Air Heater (IAH) 15 - Intake Air Temperature (IAT) Sensor 2 16 - Fuel Heater 17 - A/C Low Pressure Switch (C67/CJ2) Page 17036 Page 2765 HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Page 10404 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 19614 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 6724 Page 8034 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. 6. Install the range selector lever cable heat shield (2). 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. Page 5091 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 11858 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 10826 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 7186 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7764 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 13152 Page 2705 Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Instrument Panel Fuse Block INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. Page 10954 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JD9) Rear Brake Rotor Replacement (JD9) Page 19590 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 15000 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 15183 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove the HVAC module. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair) . 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. 3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal. 4. If equipped remove the screws from the HVAC module assembly. 5. Remove the evaporator cowl gasket from the evaporator. 6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1) Page 20538 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19510 Module Circuit Function Icons Page 6846 Page 19603 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 17245 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 2896 Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 12197 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 13524 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 8989 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 12775 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Page 20916 Washer Fluid Heater: Service and Repair Windshield Washer Solvent Heater Replacement Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 18907 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 7073 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 20280 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Page 18578 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 6000 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 11494 Front Axle (NP8) 1 - Frame 2 - X110 (NQF/NQG/NQH/NP2) 3 - Front Axle Housing 4 - Front Drive Axle Actuator (NQF/NQG/NQH) Page 1885 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 12691 Page 18315 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Page 13602 Page 16921 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 12765 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 524 Page 5509 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 20893 Disclaimer Service Procedure Service Procedure Technicians are to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. If a customer refuses to have this safety recall performed on their vehicle, dealers are to provide the customer with a copy of the "Notice to Customer" document provided in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. A labor code is provided for customers who refuse the repair. This labor code will not close the recall. If the customer, or a new owner, decides at a later date to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. This service procedure will permanently disable and remove the heated windshield washer fluid system. After performing the procedure, dealers are to issue a $100 USD/$105 CDN check to the customer of record as compensation for the loss of this feature (see Q&A; section of this bulletin for additional details). Involved vehicles currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Fuse Removal FUSE REMOVAL 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, 2007-2009 Chevrolet Avalanche, Silverado (GMT900), Suburban, Tahoe, 2007-2009 GMC Sierra (GMT900), Yukon and Yukon XL 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block is located in the engine compartment on the driver side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Page 5860 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9041 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 18056 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) Page 17480 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3067 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 4630 Note The sight shield mounting fastener must be installed and tightened. Failure to properly tighten the sight shield mounting fastener may result in an open High Voltage Interlock Circuit (HVIC) condition and DTCs. 1. Install the sight shield onto the ball studs (2) and tighten the sight shield mounting fastener (1). Tighten the fastener to 5 Nm (44 lb in) . 2. Install the fender brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 3. Enable high voltage. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 5701 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 3006 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 20539 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 13435 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 10222 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 13750 X209 Inline Harness Connector End Views X209 Chassis Harness to Rearview Camera Jumper Harness (SVA) Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 4645 10. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 11. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seal. * If pressure remains at the specified value, proceed to the next step. 12. Remove all GE-48494 - adapter kit components. 13. Remove the PIM cover retaining bolts (1). 14. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 15. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Page 17143 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Page 8287 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7591 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 18803 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 5667 Page 9495 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half ofJ 36652-1 orJ 36652-2 . Page 1919 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 108 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 11196 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 7527 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 13221 Page 19186 For vehicles repaired under warranty, use the table. Disclaimer Page 6275 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 19525 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 6254 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 9842 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 19550 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 11763 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 5258 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Page 12298 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 13309 Page 11203 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 8054 Page 9656 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Page 14433 8. Install the following parts onto the steering column shaft assembly: 1. Lubricate the steering shaft upper bearing inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. The steering shaft upper bearing inner race (1) 3. The steering shaft upper bearing inner race seat (2) 4. The steering shaft upper bearing spring (3) 5. Lubricate the turn signal switch cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. The turn signal switch cancel cam (4) 7. The turn signal switch cancel cam position plate (5) 9. Install the new steering shaft lock plate retaining ring onto the steering shaft using compressorJ 23653-SIR and adapterJ 42137 . 10. Install the automatic transmission control assembly. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement) . 11. Install the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement) . 12. Install the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Removal and Replacement/Ignition Lock Cylinder Case Replacement) . 13. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Steering Column/Service and Repair/Turn Signal Multifunction Switch Replacement) . 14. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 15. Install the steering column. Refer to Steering Column Replacement (Non-Hybrid) (See: Steering Column/Service and Repair/Steering Column Replacement)Steering Column Replacement (Two Mode Hybrid) (See: Steering Column/Service and Repair/Steering Column Replacement) . Page 12284 Module Circuit Function Icons Page 19432 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 19589 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2695 Fuse Block - I/P Top View Page 6602 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Page 15110 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 19653 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Page 11933 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 4439 Drive Motor Generator Battery Control Module X5 (HP2) Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Page 4643 7. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 8. Rotate the drive motor generator control module assembly onto the PIM cover. 9. Remove the APM to PIM mounting fasteners (1). 10. Remove the APM (2) and discard the coolant seal (3). 11. Remove the drive motor generator power inverter coolant pipe bolts (4, 7). 12. Remove the drive motor generator power inverter coolant pipes (5, 8). 13. Remove and discard coolant seals (6, 9). Installation Procedure Page 3661 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 15313 Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Engine - Valve Lifter Tick Noise At Start Up Lifter / Lash Adjuster: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 7363 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2227 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 5832 Page 9092 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13158 Fuse Block - Underhood X5 Page 5735 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 8804 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2897 Devices and Sensors Page 13740 X176 Engine Harness to Transmission Harness (M99) Page 1167 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Outside Rearview Mirror Courtesy Lamp Replacement Courtesy Lamp: Service and Repair Outside Rearview Mirror Courtesy Lamp Replacement Outside Rearview Mirror Courtesy Lamp Replacement Page 6130 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 9440 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution) . Note Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 6. Holding the J 8614-01 - holder , tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. Page 16329 Driver/Vehicle Information Display: Diagrams Component Connector End Views Driver Information Center (DIC) Switch (Except MEX/8S8) Page 12970 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 7025 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Clearance Production............................................................................................................0.023-0.065 mm (0.0009-0.0025 in) Connecting Rod Bearing Clearance Service....................................................................................................................0.023-0.076 mm (0.0009-0.003 in) Connecting Rod Bore Diameter - Bearing End................................................................................................................56.505-56.525 mm (2.224-2.225 in) Connecting Rod Bore Out-of-Round - Bearing End Production.................................................................................0.004-0.008 mm (0.00015-0.0003 in) Connecting Rod Bore Out-of-Round - Bearing End Service.......................................................................................0.004-0.008 mm (0.00015-0.0003 in) Connecting Rod Side Clearance.......................................................................................................... ..................................0.11-0.51 mm (0.00433-0.02 in) Connecting Rod Bolts - First Pass.................. .................................................................................................................................................20 Nm (15 lb ft) Connecting Rod Bolts - Final Pass......................................................................................... ..................................................................................85 degrees Page 2161 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. Page 12363 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 3018 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 20211 Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 20553 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 17039 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Spring Jounce Bumper Replacement (2500 Series) Removal Procedure Note The following service procedure is for 2500 series vehicles. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Remove the nut from the jounce bumper stud. 4. Remove the jounce bumper. Installation Procedure 1. Install the jounce bumper. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the nut to the jounce bumper stud and tighten to 30 Nm (22 lb ft) . 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 4. Lower the vehicle. Page 12749 X305 Body Harness to Passenger Seat Harness (Except AN3/MEX) X309 Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 13843 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 12317 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 5955 Body Control Module (BCM) X6 Page 6909 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 1669 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 16702 Speaker - Left Front (UQA) Speaker - Left Front Tweeter (Except MEX) Page 20626 5. Remove the rear sliding window motor/module nuts (2). 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Page 869 Auxiliary Battery Relay: Connector Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxilary Battery Relay 5 - X122 Page 14780 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13506 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Specifications Information Bus: Specifications Fastener Tightening Specifications Page 20424 Switch Position Icons Page 5747 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 14202 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 19618 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 20529 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1447 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 1065 Page 20135 Page 2876 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 19526 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 8073 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 805 Page 14212 1. Install the lower ball joint in the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement) . 2. Install upper ball joint in the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Suspension/Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Suspension/Control Arm/Service and Repair/Upper Control Arm Replacement) . 3. Install the outer tie rod end in the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 4. Install the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Suspension/Wheel Hub/Service and Repair) . 5. Install the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 6. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 7. Remove the support and lower the vehicle. 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications) . Page 20325 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 15252 Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 640 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 15618 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Page 9901 Page 8765 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9876 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Page 12151 Page 13005 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 14272 Note It may be necessary to rotate the front tire and wheel assembly while installing the power steering assist motor to in order for it to mesh with the steering gear properly. 2. Position the power steering assist motor (2) and seal (3) to the steering gear. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the power steering assist motor bolts (1). Tighten the bolts to 13 Nm (115 lb in). 4. Connect the power steering assist motor electrical connector at the torque sensor. 5. Route the power steering assist motor electrical harness back through the engine compartment to its previous position and secure the lower part of the wiring harness to the frame. 6. Install the steering linkage shield (2) and the steering linkage shield bolts (1). Page 7901 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17867 Instrument Panel Upper Compartment Replacement Instrument Panel Upper Compartment Replacement Page 12330 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 12056 Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 6175 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 19617 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 5898 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector (1). 4. Remove the HO2S clip from the engine wiring harness clip (4). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 5. Remove the HO2S (2). Page 6459 10. Remove the EVAP canister vent solenoid from the vehicle. Installation Procedure 1. Position and install the EVAP canister vent solenoid to the vehicle. Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 18343 8. Remove the front to bolts located at the motor base first. 9. With the aid of an assistant, remove the remaining bolts (1) that secure the module (2) to the roof ring. Lower and remove the sunroof module assembly out through the passenger side door. 10. If you are replacing the sunroof module assembly, remove the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . Installation Procedure 1. If you are replacing the sunroof module assembly, install the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . 2. With the aid of an assistant, position the sunroof module assembly to the roof ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Install the 4 bolts (1) that secure the module (2) to the roof ring. Page 2790 Page 8748 Page 8648 Page 18415 Head Rest: Service and Repair Head Restraint Guide Replacement Head Restraint Guide Replacement Interior - Seat Memory Inopertive After Air Bag Deploys PROM - Programmable Read Only Memory: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3781 9. Remove the differential carrier left side bolts. 10. Lower the differential carrier. 11. For 2500 series vehicles, remove the differential carrier right side nuts. 12. Remove the differential carrier upper mounting bolt and nut. 13. Remove the differential carrier lower mounting bolt and nut. Page 13820 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Page 826 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6953 Camshaft Position (CMP) Sensor (Diesel) Page 11095 5. Install the BPMV bolts (1) and tighten to 9 Nm (80 lb in) . 6. Position the hydraulic control unit and bracket assembly (1) to the frame rail. Slide the assembly toward the left of the vehicle and install the assembly to the vehicle frame. Page 20076 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Page 6653 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (With CH 47976) Fuel Injector Diagnosis (w/CH 47976) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. The CH-47976, is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be down loaded for storage and printing. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Special Tools CH-47976 Active Fuel Injector Tester Component Testing Fuel Injector Coil Test 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. Page 3897 17. Remove the engine harness clip (1) bolt (3). 18. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor. 19. Disconnect the generator control module electrical connector. 20. Gather the engine harness branches and tie the harness up out of the way to the cowl panel. 21. Disconnect the EVAP canister purge tube (1) quick connect fitting from the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 22. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . Page 11877 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Specifications Brake Shoe: Specifications Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 19442 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7368 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 11881 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Locations Auxiliary Water Pump Relay: Locations Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 12195 Page 229 Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Page 5263 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 5158 Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (3). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (6). Page 12045 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement (1500) Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 15944 Seat Belt Retractor: Service and Repair Rear Seat Belt Retractor Replacement (Extended Cab) Rear Seat Belt Retractor Replacement (Extended Cab) Page 20545 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 6411 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 4519 Drive Motor Control Module: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 8173 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 9304 During your call with GM TAC on a current case, you may be advised to send a copy of the Tech 2(R) or VDR Snapshot Data to the TAC e-mail box. U.S. Dealers - send to e-mail box [email protected] Canadian Dealers - send to e-mail box [email protected] Please complete the following: - Be sure to review the procedures listed above for uploading and sending a Snapshot via TIS2WEB. - If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink Website in the articles (December 2002, December 2003, July 2004 and January 2006). - Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email can not be processed and will be deleted. Please send only REQUESTED Snapshot Data to the TAC e-mail box. Disclaimer Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 9761 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 4858 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 7405 Transfer Case Actuator: Locations MP 1625/1626-NQF - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 - Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor - O-Ring - Seal 15 - Transfer Case Rear Half 16 Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 22 - Transfer Case Two/Four Wheel Drive Actuator Assembly 23 - Transfer Case Two/Four Wheel Drive Actuator Seal Page 13027 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 4098 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: Give freezing protection down to -34°F (-37°C). Give boiling protection up to 265°F (129°C). Protect against rust and corrosion. Help keep the proper engine temperature. Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. DRIVE MOTOR/GENERATOR CONTROL MODULE (DMCM) COOLING SYSTEM Always use the pre-mixed 50/50 mixture of de-ionized water and DEX-COOL (silicate-free) coolant. Page 2307 Compression Check: Testing and Inspection Engine Compression Test Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. Note When performing an engine cylinder compression test for the RPO-LFA engine, note that this engine has a camshaft position actuator with a late intake valve closing feature and a 29 degree retard park position. With the actuator parked in a retard position, the effective compression of the engine is reduced during cranking. Compression values on the gage will be lower than a typical small block engine that does not have this feature. 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition key in the OFF position. 3. Charge the battery if the battery is not fully charged. 4. Disable the fuel and spark by removing the Fuel Pump relay and Powertrain relay. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) for the Fuse Block - Underhood Label. 5. Remove the spark plug wires from the spark plugs. 6. Remove all of the spark plugs. Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. 7. Install a compression gage to the cylinder to be tested. 8. Start with the compression gage at zero and crank the engine 3-5 seconds using the ignition key. 9. Return the ignition key to the OFF position. 10. Measure the compression for each cylinder. Record the readings. 11. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any 1 cylinder is 862 kPa (125 psi), the lowest allowable pressure for any other cylinder would be 607 kPa (88 psi). (862 kPa x 70% = 607 kPa) (125 psi x 70% = 88 psi). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. 12. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 13. Reinstall the Fuel Pump relay and Powertrain relay. 14. Using the scan tool, clear all diagnostic codes. Page 7463 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 15572 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 3850 13. For 1500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 100 Nm (74 lb ft). 14. Position the left side transmission cover and install the cover bolt. Tighten the bolt to 12 Nm (106 lb in). Page 11013 Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4911 Page 4004 14. Install EN-48853 to the front cover. 15. Install the crankshaft balancer bolt until snug. Do not overtighten. 1. Tighten the oil pan to front cover bolts to 25 Nm (18 lb ft). 2. Tighten the engine front cover bolts to 25 Nm (18 lb ft). 16. Remove the tools . 17. Position the CMP sensor. 18. Connect the engine harness electrical connector (2) to the CMP sensor wire harness electrical connector. 19. Connect the camshaft position sensor wire harness electrical connector (1) to the CMP actuator magnet. 20. Install a NEW crankshaft front oil seal. 21. Install the water pump. Page 18267 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Page 17606 Hood Stop: Service and Repair Hood Stop Bracket Replacement Hood Stop Bracket Replacement Page 9286 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Drivetrain - Clunk Noise At A Stop Or From Launch Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 4118 Page 4669 Drive Motor Control Module: Description and Operation Drive Motor Generator Control Module Description and Operation Overview The drive motor generator power inverter module (PIM) assembly converts high voltage direct current (DC) electrical energy to 3 phase alternating current (AC) electrical energy. The accessory DC power control module (APM) converts high voltage DC electric energy into low voltage (14V) and intermediate voltage (42V) in order to charge the vehicles accessory battery and supply electric energy to the 42V power steering system. The APM and PIM are fastened together and are referred to as the drive motor generator control module assembly. The drive motor generator control module assembly is cooled with pre-mixed Dexcool(R) circulating through a cooling system that is separate from the engine cooling system. The hybrid cooling system utilizes a heat exchanger at the front of the vehicle and electric pumps to circulate the coolant. The engine control module (ECM) monitors a temperature sensor in the hybrid cooling system and operates the radiator fan and the hybrid coolant pumps in response to system temperature. High Voltage Circuits Direct Current (DC) The drive motor generator control module assembly is connected to each pole of the high voltage (HV), direct current (DC) drive motor generator battery. Both of the negative and positive HV DC battery poles are isolated from the vehicle chassis by a specific amount of resistance. Each HV DC cable is switched ON or OFF by a high voltage, high current contactor relay contained within the drive motor generator battery assembly. All HV DC negative and positive DC cables are individually shielded and orange in color to alert the technician to the potential presence of high voltage. The electric air conditioning compressor high voltage DC cables are externally connected at the drive motor generator control module assembly. The APM and PIM share an internal connection that supplies the APM with high voltage DC current. Three Phase Alternating Current (AC) Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician to the potential presence of high voltage. Intermediate and Low Voltage Circuits The APM converts high voltage 300V DC current into both intermediate voltage, 42V, and low voltage, 12V, current. Intermediate Voltage 42V Direct Current Intermediate voltage 42V cables are individually shielded and are blue in color to alert the technician to the potential presence of intermediate voltage. Low Voltage (12V) Direct Current Low voltage (12V) cables on the hybrid-electric vehicle do not require unique coloring or servicing procedures. Drive Motor Generator Power Inverter Module (PIM) Assembly Overview Contained within the PIM assembly are the hybrid powertrain control module (HPCM), and two motor control modules (MCM). Each MCM controls its respective motor generator. All three modules are flash-programmable micro-processors. Hybrid Powertrain Control Module (HPCM) Location The HPCM is a non-serviceable, flash-programmable micro-processor contained within the PIM assembly. Operating Functions The HPCM is the main controller of hybrid operation. The HPCM determines when to perform hybrid operation modes such as engine Auto-stop and regenerative braking. The HPCM also operates in conjunction with the battery energy control module (BECM) to determine when to enable and disable the DC high voltage circuits. Each MCM operates the applicable electric motor generator based upon HPCM commands. Communication and Hosted Diagnostics The HPCM is the host controller for diagnostic trouble code (DTC) information for the following control modules: Page 10872 Brake Pad: Service and Repair Front Disc Brake Pads Replacement (JH6, JH7) Front Disc Brake Pads Replacement (JH6, JH7) Page 4658 Drive Motor Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 14351 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Page 17477 occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Page 11888 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Interior - Lint Accumulation On Ebony Colored Seats Head Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 17457 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 5987 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 8246 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Front Wheel Speed Sensor Replacement Page 13565 Junction Block - Right I/P (Wire Entry) Page 4247 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 20433 Page 14525 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Shock Absorber Replacement Shock Absorber Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Support the rear axle. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure Page 17601 Hood Shock / Support: Service and Repair Hood Strut Replacement Hood Strut Replacement Page 8199 Page 1625 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Page 8505 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check See: Testing and Inspection/Component Tests and General Diagnostics Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement Air Distributor Duct Replacement Page 3907 25. Untie the engine harness branches from the cowl panel and position over the engine. 26. Connect the engine harness electrical connector (2) to the ECT sensor. 27. Position the engine harness clip (1) to the generator bracket and install the bolt (3). Tighten the bolt to 9 Nm (80 lb in). 28. Connect the generator control module electrical connector. 29. Connect the engine harness electrical connectors (5) to the right side fuel injectors. 30. Install the engine harness clip (4) to the ignition coil bracket stud. 31. Connect the engine harness electrical connector (3) to the throttle actuator. 32. Connect the engine harness electrical connector (2) to the ignition coil harness electrical connector. 33. Install the CPA retainer (1). Page 7078 Spark Plug: Application and ID Ignition System Specifications Page 13588 Fuse Block - Underhood X2 Page 9900 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 20499 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 19428 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6728 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Exhaust - Muffler Heat Shield Buzz During Operation Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Page 4119 Page 3515 4. Remove the CMP actuator (235) and timing chain (208). 5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Installation Procedure Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Page 1074 Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 7944 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 13289 Fuse Block - Auxiliary X1 (HP2) Page 7858 Page 3048 Junction Block - Left I/P X9 (except MEX) Page 11393 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 12027 Page 4696 13. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 14. Clean the sealing surface of the PIM cover as necessary. 15. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 16. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . 17. Install the ground strap (2) and bolt (1). Tighten the bolt to 22 Nm (16 lb ft) . Page 14081 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 15760 Disclaimer Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 573 JX221 Branching Point: Diagrams JX221 Splice Pack Connector End Views JX221 Page 13394 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 18784 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 2881 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 871 Page 17712 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring recepticle (4). Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner Bolts.............................................................................................................. ..........................................................25 Nm (18 lb ft) Page 5130 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 12705 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) Page 20397 Page 4896 Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 20238 Page 12401 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 11892 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 5813 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Important: The following steps must be completed before using the symptom tables. 1. Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation (See: Description and Operation) . Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics) . Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) * Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not Communicate with Low Speed GMLAN Device ) * Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device (See: Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device) Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Page 17330 1 - Door Frame 2 - Door Lock Switch -Driver (AU3) 3 - Speaker -Left Front 4 - Door Latch -Driver Driver Door Components (AN3/DL3) Page 4155 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8628 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 2340 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct (3) from the throttle body and MAF/IAT sensor. Installation Procedure Note Ensure that the notch in the air cleaner outlet duct throttle body aligns with the boss on top of the throttle body. 1. Install the air cleaner outlet duct (3) to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 4694 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in) . 4. Rotate the drive motor generator control module assembly onto the APM. 5. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 6. Plug the remaining coolant pipe with GE-48494 adapter kit plug and clamp (1). 7. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 8. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seals. * If pressure remains at the specified value, proceed to the next step. 9. Remove all GE-48494 - adapter kit components. Page 5036 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Tire Monitor System - Tire Pressure Light Stays ON Door Module: Customer Interest Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Page 13166 Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 2734 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 7016 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 8983 Page 18544 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Page 20077 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 1094 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Tire Monitor System - Tire Pressure Light Stays ON Door Module: Customer Interest Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Page 4431 Battery Bus Cover: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 2717 Junction Block - Left I/P X7 (JF4) Page 1360 Page 20136 Page 18158 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Page 13195 Page 13897 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse Block/Diagrams/Connector Views) to locate the electrical center where the relay exists. Note * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 15432 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 11107 13. Remove the 5 transfer tubes (1). 14. Remove and discard the 5 upper transfer tube O-ring seals (2). 15. Remove discard the 5 lower transfer tube O-rings seals (3). Installation Procedure 1. Assemble the 5 transfer tubes (1) to 5 new upper transfer tube O-ring seals (2). 2. Install the 5 new lower transfer tube O-ring seals (3). 3. Lubricate the new O-ring seals with GM approved brake fluid from a clean, sealed brake fluid container. 4. Install the transfer tube assemblies to the brake modulator valve assembly. Page 5105 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 13465 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 19050 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Component Views Page 9417 7. Remove the collapsible spacer. Note When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 3030 Fuse Block - Auxiliary X3 (HP2) Page 5679 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 1939 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 12022 Page 9464 Ensure that the outer bearing assembly rotates freely in the hub 5. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the wheel hub over and seat the outer bearing assembly against the retaining ring. 6. Turn the wheel hub over and install the inner bearing cup. 7. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 8. Install the inner bearing. Note Ensure the seal is fully seated in the hub bore. Page 6995 7. Remove the generator control module 3 phase cable clip nut (1). 8. Remove the generator control module 3 phase cable clip from the engine bracket (2). 9. Reposition the generator control module 3 phase cables out of the way. 10. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 11. Working through the wheel opening, remove the engine bracket bolts (2). 12. Lower the vehicle. 13. Remove the engine bracket nut (1) from the ignition coil bracket stud and remove the bracket (3). Page 13409 Page 9316 Actuator: Diagrams Component Connector End Views Front Drive Axle Actuator (NQF/NQG/NQH) Page 11880 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6487 11. If equipped with 4WD, install the fuel hose/pipe clip (1) to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft) . 14. Position and install the BPMV. Refer to Brake Pressure Modulator Valve Replacement () . 15. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 16. Lower the vehicle. Page 13837 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (A48) Page 12404 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 8152 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 19400 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 19350 Harness Components Service and Repair Heater Hose: Service and Repair Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Diagrams Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Page 7979 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 10175 Locations Air Bag Deactivation Indicator: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Rear Axle Shaft Seal and/or Bearing Replacement Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement Special Tools * J 2619-01 - Slide Hammer W 1/2 x 13 Adapter * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 21128 - Axle Pinion Oil Seal Installer * J 23690 - Axle Bearing Installer * J 44685 - Rear Axle Seal and Bearing Remover * J 45857 - VSES Wheel Bearing Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 4. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair) . Note If the vehicle is equipped with VSES, proceed to step 5. 5. Using the J 44685 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal. 6. Using the J 45857 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal, bearing and the wheel speed sensor reluctor ring, if equipped. Installation Procedure 1. Install the rear wheel speed sensor reluctor ring, if equipped. * For vehicles with the HP2 (Hybrid) option, refer toRear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement) . * For vehicles that are NON-Hybrid less than 3900 kg (8600 lbs) GVW, refer toRear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement) . * For vehicles that are NON-Hybrid greater than/equal to 3900 kg (8600 lbs) GVW, refer toRear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement) . Page 12690 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L and NQF/NQH) Page 4944 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (Gas with LY6) Front Side Door Sill Trim Plate Replacement (Extended Cab) Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Extended Cab) Front Side Door Sill Trim Plate Replacement (Extended Cab) Page 13124 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 12658 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (Except MEX) Page 7226 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 20659 Window Switch - Left Rear (Crew Cab with A31/Extended Cab with ABV) Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 20337 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 5215 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Transmission 5 Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 X175 (MW7) Diagrams Negative: Diagrams Component Connector End Views Battery - Left (-) (Auxiliary Battery Negative Cable) (6A6) Battery - Left (-) (Auxiliary Battery Negative Cable) (TP2) Battery - Left (-) (Battery Negative Cable) (Diesel) Battery - Right (-) (Battery Negative Cable) (Gas) Battery - Right (-) (Starter Cable) (Diesel) Page 10736 20. Slide the EBCM/BPMV and bracket assembly (1) toward the center of the vehicle and remove the assembly from the vehicle frame. 21. Place the EBCM/BPMV and bracket assembly on a clean work surface. 22. Remove the BPMV bolts (1). Diagrams Shifter A/T: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) Page 20331 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 11687 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 11070 Page 5956 Body Control Module (BCM) X7 (Except MEX/A52) Page 3968 4. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned. Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 5. Remove the camshaft sprocket bolt (206). 6. Remove the camshaft sprocket (205) and timing chain (208). 7. Remove the timing chain tension bolts (231) and tensioner (232). Page 8181 Control Solenoid Valve Assembly X3 (MYC/MYD) 1-2 Shift Solenoid (SS) Valve (M30) Page 20808 For vehicles repaired under warranty, use the table. Disclaimer Page 5511 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 19823 Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump (Diesel with 31 Series without NQZ) Fuel Pump and Sender Assembly - Front (Gas Except MEX) Page 8440 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 18492 Seat Lumbar Vertical Motor - Driver (AN3) Seat Lumbar Vertical Motor - Passenger (AN3) Page 2868 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Engine Harness Routing - Left Side (4.3L) Page 14730 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 6714 Fuel System Diagnosis (w/FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Important: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Ignition OFF, all accessories OFF, install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4 - 310.3 Page 10739 28. Remove the EBCM (1). Installation Procedure 1. Install the EBCM (1) to the BPMV, if removed. Page 11316 * Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement)Master Cylinder Reservoir Replacement (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Replacement (J92)) . Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Brake Pipe Replacement (Master Cylinder to ABS Controller))Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7))Rear Brake Hose Replacement (Frame to Axle - JD9, JF3, w/JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (2500 Series))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JD9)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) orFront Brake Caliper Replacement (JD9, JF3, JF7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) orRear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement () * Brake Pressure Modulator Valve Replacement () 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . Page 8323 Page 20647 Door Lock/Window Switch - Driver X3 (AN3/DL3) Page 385 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control relay electrical connector. Note It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Page 9878 Page 6331 1. Install the a NEW CMP actuator solenoid valve until snug. With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the CMP actuator solenoid valve. 1. Tighten the solenoid valve a first pass to 65 Nm (48 lb ft). 2. Tighten the solenoid valve a final pass and additional 90 degrees using J 45059 . 3. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . BW 4485-NR3 - Transfer Case Seals and Gaskets: Service and Repair BW 4485-NR3 - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Tools Required * J 8092 Driver Handle * J 43484 Output Shaft Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Important: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft. 4. Remove the front output shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal. 5. Pry the inner seal race forward. Page 919 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5293 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct (3) from the throttle body and MAF/IAT sensor. Installation Procedure Note Ensure that the notch in the air cleaner outlet duct throttle body aligns with the boss on top of the throttle body. 1. Install the air cleaner outlet duct (3) to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 228 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 12586 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Page 15960 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Page 15537 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 3102 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Page 14618 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12174 Page 19728 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 20837 Page 20383 Park/Turn Signal Lamp - Upper Left Page 5922 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6689 Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas Except LU3/LY6) Instruments - Compass/Temperature Display Information Outside Temperature Display: Technical Service Bulletins Instruments - Compass/Temperature Display Information INFORMATION Bulletin No.: 07-08-48-004A Date: June 13, 2008 Subject: Information on Outside Temperature and Compass Displays on Inside Rearview Mirror Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 with RPO DF5 or TQ5 (Intellibeam(R)) Inside Rearview Mirror Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 07-08-48-004 (Section 08 - Body and Accessories). Some dealers/customers may notice that the outside temperature and compass are not displayed in the inside rearview mirror. The mirrors are usually turned on when the vehicles leave the assembly plant, but there may be situations when the mirrors may be turned off by the transport company, dealer personnel and/or the customer. If you experience a vehicle that has an inoperative compass and temperature display, make sure that the function is turned on in the mirror. Briefly press the on/off button on the left side of the mirror (RPO DF5) to turn the display on. The green LED that is on the left side of the mirror is for the automatic dimming function. There has been some confusion in which a customer sees the green LED and thinks that this automatically means the compass and the temperature display should be illuminated. So the customer may not try to turn the function on. If the vehicle is equipped with the Intellibeam(R) (RPO TQ5) mirror, press and hold the auto headlamp button on the left side of the mirror for 3-5 seconds. The Warranty Parts Center (WPC) has found that several of the mirrors were returned with the function turned off and there were no problems found with the mirror. Disclaimer Page 12453 Junction Block - Right I/P X3 Page 20008 Page 20447 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 7794 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11804 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 15699 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series with Crew Cab Except ASF) Page 13001 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 15624 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 11719 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19410 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2716 Junction Block - Left I/P X5 (SPO Alarm) Page 4744 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 4968 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 7153 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 14465 Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement Removal Procedure Note The following service procedure applies to vehicle equipped with cast iron lower control arms only. For those vehicles equipped with an aluminum lower control arm, the ball joint is NOT serviced separately. If the ball joint in the aluminum lower control arm is found to have excessive wear and is damaged replace the lower control arm as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Remove the lower control arm from the vehicle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement) . 4. Place the lower control arm in a vise. 5. Using a chisel, remove the securing crimps from the ball joint body, if equipped. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure Note Use the outer flange of the ball joint in order to press the ball joint into place. 1. Install the ball joint using a press. 2. Place the lower control arm a bench vise. Note Use the replaced ball joint as a reference. 3. Using a punch, install the crimps to the ball joint. 4. Install the lower control arm in the vehicle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement )Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement) 5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 6. Remove the safety stand and lower the vehicle. 7. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications) . Page 11263 Parking Brake Cable: Removal and Replacement Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling) . 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Disconnect the front park brake cable (2) from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector (1). 5. Disconnect the left park brake cable (1) and the right park brake cable (2) from the equalizer bar (3) on the intermediate park brake cable. Page 18349 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Page 11732 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 5785 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 2375 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Tune-up and Engine Performance Checks/Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Page 8077 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 10290 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 4545 Drive Motor Control Module: Service and Repair Drive Motor Generator Power Inverter Module Removal and Installation Drive Motor Generator Power Inverter Module Removal and Installation Special Tools * GE-48494 - Power Electronics Pressure Test Adapter Kit * J 24460-01 - Cooling System Pressure Tester Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 3. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 5963 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Locations Fuse Block: Locations Harness Routing Views Driver Door Harness Routing 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Passenger Door Harness Routing Page 19082 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15008 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Page 19484 Cruise Control: Description and Operation Cruise Control Description and Operation Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions at speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds. The following are the main components of the Cruise Control System: * The accelerator pedal * The stop lamp switch * The body control module (BCM) * The cruise control switches * The engine control module (ECM) * The throttle actuator control (TAC) motor * The vehicle speed sensor (VSS) Cruise Control Engaged The Cruise Control System will engage and adjust vehicle speeds, based on the activation of the following cruise control switches, which are located on the steering wheel: * The on/off switch * The + RES switch * The - SET switch The body control module (BCM) monitors the signal circuit of the cruise control switches. The BCM relays the cruise control switch status to the engine control module (ECM) via the GMLAN serial data circuit. The ECM uses the status of the cruise control switch to determine when to capture and maintain the vehicle speed. The ECM monitors the vehicle speed signal circuit in order to determine the desired vehicle speed. The ECM uses the throttle actuator control (TAC) motor in order to maintain the vehicle speed. For further information on the TAC System, refer toThrottle Actuator Control (TAC) System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Throttle Actuator Control (TAC) System Description) for the 4.3L engine orThrottle Actuator Control (TAC) System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Throttle Actuator Control (TAC) System Description) for the 4.8L, 5.3L, 6.0L, 6.2L or 7.0L engines. Voltage is supplied to the cruise control switch via the steering wheel control switch reference voltage circuit supplied by the BCM. The cruise control function switches are arranged in a resistive ladder design, with each cruise control function switch having a different resistance value. The BCM detects a specific voltage value that is associated with the cruise control function switch being activated. When the normally open cruise control on/off switch is turned ON, the switch closes and the BCM supplies a ground to the cruise control switch ON indicator circuit as it becomes illuminated. The BCM sends a GMLAN serial data message to the ECM indicating that the on/off switch is active. Similarly, when the normally open + RES switch or the normally open - SET switch are pressed, the switch closes and the BCM detects the predetermined voltage signal on the cruise control set/coast and resume/accel switch signal circuit. The BCM sends a GMLAN serial data message to the ECM indicating that the + RES switch or the - SET switch is active. To engage the Cruise Control System, ensure that the vehicle speed is above 40.2 km/h (25 mph), turn the cruise On/Off switch ON and momentarily press the - SET switch. The ECM will engage the Cruise Control System and record the vehicle speed. The ECM sends a GMLAN serial data message to the driver information center (DIC) in order to illuminate the CRUISE SET TO ### message. The ECM sends a GMLAN serial data message to the instrument panel cluster (IPC) in order to illuminate the Cruise Engaged indicator in the IPC. The - SET switch and the + RES switch will remain inactive when the BCM has not received the predetermined voltage signal from the on/off switch. Pressing the accelerator pedal, while the Cruise Control System is engaged, will allow the driver to override the Cruise Control System in order to accelerate the vehicle beyond the current set vehicle speed. When the accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed. The driver can also override the current set vehicle speed via the SET switch and the + RES switch. When the Cruise Control System is engaged, pressing and holding the - SET switch will allow the vehicle to decelerate from the current set vehicle speed without deactivating the Cruise Control System. When the - SET switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the - SET switch will allow the vehicle to decelerate at 1.6 km/h (1 mph) increments for each time that the - SET is momentarily pressed, with a minimum vehicle speed of 37 km/h (23 mph). Pressing and holding the + RES switch, when the Cruise Control System is engaged, will allow the vehicle to accelerate to a greater vehicle speed than the current set vehicle speed. When the + RES switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the + RES switch will allow the vehicle to accelerate at 1.6 km/h (1 mph) increments for each time that the + RES switch is momentarily pressed, with the maximum acceleration total of 16 km/h (10 mph) over the current set vehicle speed. Momentarily activating the + RES switch will recall the previous vehicle speed, after the cruise control system is disengaged by pressing the brake pedal or by activating the CANCEL switch. Cruise Control Disengaged The engine control module (ECM) disengages the cruise control operation based on the signals from the following switches: * The stop lamp switch Page 15346 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 15391 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid ............................................................................................................................. .................................................. 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 11826 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 7766 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 13115 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 13453 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 15820 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 18794 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 4197 Radiator Cooling Fan Motor Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 13272 Fuse Block - Underhood X1 Page 1553 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 4685 Drive Motor Control Module: Service and Repair Drive Motor Generator Power Inverter Module Removal and Installation Drive Motor Generator Power Inverter Module Removal and Installation Special Tools * GE-48494 - Power Electronics Pressure Test Adapter Kit * J 24460-01 - Cooling System Pressure Tester Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 3. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. Page 16632 For vehicles repaired under warranty, use the table. Disclaimer Page 3692 * Remove all traces of the original adhesive patch. * Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. * Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the engine mount bracket bolts. Tighten the bolts to 65 Nm (48 lb ft). 4. Install the engine mount. Refer to Engine Mount Replacement - Left Side (1500 LY2) (See: )Engine Mount Replacement - Left Side (1500 Except RPOs LY6, LY2) (See: )Engine Mount Replacement - Left Side (2500 LY6) (See: ) . Page 19729 Disclaimer Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 19281 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Page 7704 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 1454 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Page 19457 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 15021 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 3776 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Special Tools * DT-47731 1/2 in Line Quick Release Tool * J 28585 Universal Snap Ring Remover for the 5/8 in Line Removal Procedure 1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation. 2. Install the DT-47731 onto the engine oil cooler (EOC) pipe, or use the J 28585 3. Slide the DT-47731 toward the EOC pipe fitting, or use the J 28585 Page 6497 Evaporative Emissions Hose: Service and Repair Evaporative Emission Line Replacement Engine Evaporative Emission Hoses/Pipes Replacement - Engine Removal Procedure Note Clean all evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the EVAP line quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the EVAP line quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Installation Procedure Page 15378 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 6958 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: All Technical Service Bulletins Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 4506 Drive Motor Power Cable: Service and Repair Generator Control Module 3-Phase Cable Assembly Replacement Generator Control Module 3-Phase Cable Assembly Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Perform the high voltage disabling. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 2. Remove the power inverter module (PIM) 3 phase cable terminal fasteners (1). 3. Remove the PIM 3 phase cable mounting fasteners (2, 4). 4. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box. 5. Remove and discard the seals (6). Page 7355 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Component Locations Seat Bladder: Component Locations Passenger Compartment/Roof Component Views Passenger Seat Components - 1 of 2 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 10284 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7284 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 13559 Junction Block - Left I/P X10 (except MEX) Locations Brake Light Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 19588 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13714 X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (NQF/NQH/HP2 Except Late Production with 4.8L/5.3L/6.0L/6.2L) Page 9223 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 4536 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 5. Remove the drive motor generator power inverter control module (PIM) 3 phase cable terminal fasteners (1). Caution: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper: * Cable sealing * Electrical shielding * Terminal position assurance 6. Remove the PIM 3 phase cable mounting fasteners (2, 4). 7. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box. 8. Remove and discard the seals (6). Page 17352 1. Install the door lower striker (2). 2. Install the spacer, if equipped. 3. Install the door lower striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Tighten the lower striker bolts. Tighten the door lower striker bolts to 24 Nm (18 lb ft). Page 18958 1 - Door Frame 2 - Door Lock Switch -Driver (AU3) 3 - Speaker -Left Front 4 - Door Latch -Driver Driver Door Components (AN3/DL3) Page 18748 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 15826 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Service and Repair Refrigerant: Service and Repair Refrigerant Recovery and Recharging (HP2) Special Tools * J 43600 ACR 2000 Air Conditioning Service Center * HP2 A/C Oil Injector A/C Oil Injector Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only polyolester refrigerant oil (POE) for internal circulation through the R1344a A/C system and only use 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (Non-HP2) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If POE oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. POE Oil can be injected into a charged system usingHP2 A/C Oil Injector .For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (Non-HP2). Page 20385 Tail/Stop and Turn Signal Lamp - Lower Left Page 2852 Junction Block - Right I/P X2 Page 19459 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 19121 Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side Endgate Lower Hinge Replacement - Body Side Page 18553 Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Page 17771 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 5102 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 6749 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 8001 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Page 7780 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10182 Page 7976 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 7951 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 12459 Junction Block - Rear Lamps X3 Page 8899 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 8000 Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Page 8120 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 10390 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 12073 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 314 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 6033 Page 20455 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 14474 7. Remove the lower shock module bolts from the lower control arm. 8. Using the J 43631 and the J 45851 , remove the lower ball joint from the steering knuckle. Page 1963 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 18048 Page 7201 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 10026 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Page 8472 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components (Diesel) Page 5429 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 14442 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 159 Disclaimer Page 10875 Page 16043 Seat Position Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 12218 Fuse Block - Auxiliary X3 (HP2) Page 3009 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 5244 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 20053 Voice Recognition System - Won't Recognize Bluetooth(R) Steering Mounted Controls Communication Module: Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 20782 Note Use a suitable tool to release the tabs (1) from the rear sliding window pulley (3). 4. Remove the rear sliding window pulley covers (2). 5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame. Adjustments Differential Output Shaft Bearing: Adjustments Inner Axle Shaft Shim Adjustment Special Tools * J 34672 Depth Micrometer * J 34673 Flat Gage Bar * J 8001 Dial Indicator Set The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced: * The inner axle shaft * The inner axle shaft housing * The clutch shaft * The differential carrier case * The ring and pinion gears * The differential assembly * The differential bearings * The carrier connector Front drive axle clutch shims are available in the following sizes: 1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (See: Service and Repair) . Page 777 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 5558 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 4417 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 15245 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 7721 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 11736 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 19546 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 14341 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 18895 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Page 2071 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Front Upper Speaker Replacement Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Page 13859 Page 2507 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities andAdhesives, Fluids, Lubricants, and Sealers (See: Transmission and Drivetrain/Differential Assembly/Specifications/Fluid Type Specifications) . 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Page 3584 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2817 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 5372 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 4783 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 13267 Page 8139 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15338 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 11435 4. Tighten the trailer brake control module bolts (1) to 9 Nm (80 lb in) . 5. Connect the trailer brake control module electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 7. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 9181 Disclaimer Page 846 Air Bag Control Module: Connector Locations Harness Routing Views Body Harness Routing (Crew Cab except HP2) 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 Page 12680 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Page 1277 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (AN3/DL3) Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 1346 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 17525 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 2770 Page 8281 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 2907 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 9040 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 20563 ‹› If greater than the specified range, replace the relay. Rear Window Defogger Grid Test 1. Ignition ON, turn on the rear window defogger. 2. Verify that a test lamp illuminates between each rear window defogger grid line and ground. The test lamp should be off when testing at the ground side of the grid and get brighter as the test lamp moves closer to the voltage supply side of the grid. The test lamp should be dim when testing each grid line in the middle. ‹› If the test lamp remains bright at the middle of the grid line, test for an open between the test point and the ground side of the grid. ‹› If the test lamp remains off at the middle of the grid line, test for an open between the test point and the voltage supply side of the grid. Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Rear Window Replacement (See: Windows/Service and Repair/Rear Window Replacement) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for HVAC control module replacement, setup, and programming Page 8271 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 8175 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 15209 Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 8. Remove the nuts (2) from the HVAC module (3). 9. Remove the bolts (1) from the HVAC module (3). 10. Remove the HVAC module (3). Installation Procedure 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the nuts (2) to the HVAC module (3). Tighten the nuts to 9 Nm (80 lb in). 4. Install the bolts (1) to the HVAC module (3). Page 11706 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 20371 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Page 3464 Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 7. Remove the CMP actuator (235) and timing chain (208). 8. Remove the camshaft retainer bolts (204) and retainer (203). Door Ajar Indicator Description and Operation (w/AN3) Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator Description and Operation (w/AN3) Door Ajar Indicator Description and Operation (w/AN3) Door Ajar Indicator System Components The door ajar indicator system consists of the following components: * The driver door switch (DDS) * The passenger door switch (PDS) * The body control module (BCM) * The instrument panel cluster (IPC) * The driver door ajar switch * The passenger door ajar switch * The left rear door ajar switch * The right rear door ajar switch Driver Door Ajar And Passenger Door Ajar The driver door switch (DDS) and passenger door switch (PDS) receive a discrete input from the respective door ajar switch to indicate the status of the door. The DDS or PDS then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Left Rear Door Ajar And Right Rear Door Ajar The body control module (BCM) receives a discrete inputs from both the left and right rear door ajar switches to indicate the status of the rear doors. The BCM then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Page 6878 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 1334 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 10597 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Locations Oxygen Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 10228 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2577 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings) . 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations . 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. Page 16304 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Alarm Sensor - Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Alarm Sensor - Right Rear Middle (UD7) 8 - Marker Lamp - Tailgate (R05) 9 - Object Alarm Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Alarm Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 - Backup Lamp - Left Rear Rear of the Vehicle Components (Z88) Page 11017 Page 7792 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3597 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 20210 Page 20400 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 5008 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 2162 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 5648 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 20544 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12176 Fuse Block - Auxiliary X3 (HP2) Page 10157 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. 6. Install the range selector lever cable heat shield (2). 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. Page 12657 X303 Body Harness to Driver Seat Harness (Except AN3/MEX) X303 Driver Seat Harness to Body Harness (MEX/A52) Page 3205 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 13417 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 9195 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch) Disclaimer Page 10256 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6665 5. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil. 6. Position the fuel rail onto the intake manifold. 7. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Push down firmly on both sides of the rail until all injectors have been seated into their bores. 8. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 lb in). 9. Install the EVAP tube and purge solenoid. 10. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 11. Connect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 11708 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 13836 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 7404 23 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Inner 24 - Transfer Case Front Output Shaft Drive Chain Assembly 25 - Transfer Case Front Output Shaft Drive Sprocket 26 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 27 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 28 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 29 - Transfer Case Oil Pump Assembly 30 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 31 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 32 Transfer Case Rear Output Shaft Rear Bearing Assembly 33 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 34 - Transfer Case Oil Pump Suction Pipe 35 - Transfer Case Oil Pump Suction Pipe Seal 36 - Transfer Case Front Output Shaft Driven Sprocket Spacer Spring 37 Transfer Case Front Output Shaft Driven Sprocket Spacer 38 - Transfer Case Front Output Shaft Driven Sprocket 39 - Transfer Case Front Output Shaft Hole Plug 40 - Transfer Case Front Output Shaft 41 - Transfer Case Front Output Shaft Front Bearing Assembly Page 11458 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 17478 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Page 13063 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 5352 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Page 2712 Junction Block - Left I/P X2 (except MEX) Page 5083 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 9445 * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle 2. Install the outer bearing into the wheel hub. Note Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 3. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the wheel hub. Note Ensure that the retaining ring is fully and evenly seated in the groove. 4. Install the retaining ring into the groove. Page 143 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 425 4. Remove the ABS module splash shield bolts (1). 5. Remove the ABS module splash shield (1). Page 7607 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 12630 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (Except TZ0) Page 6231 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 13033 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 19446 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 14411 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 11525 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 11999 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 6071 Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 8645 Transmission Control Module (TCM) (MW7) Page 6375 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Locations Battery Temperature Sensor/Switch: Locations Generator Battery Temperature Sensor Location Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 15244 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 11492 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Front Frame and Underbody Components - 1 of 2 Page 6367 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 11411 8. Install the ABS module splash shield retainer (1). Page 12050 Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof Motor/Actuator Replacement (Extended Cab) Removal Procedure Note The sunroof motor/actuator drive shaft turns in both directions and contains no limit switches. You may replace the sunroof motor/actuator with the window panel in any position. 1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 2. Disconnect the electrical connector (1) from the motor/actuator. 3. Remove the screws (2) from the sunroof motor/actuator . 4. Pull straight down to disengage the drive gear from the cables housed within the sunroof cable drive tubes. 5. Remove the sunroof motor/actuator (3) from the sunroof module. Installation Procedure Page 16055 Antenna Mast: Service and Repair Electronic Navigation Antenna Replacement Page 19582 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 6066 Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 10436 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 272 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 1827 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 6. Remove the HO2S (1). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). Page 6771 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended/Crew Cab) Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Unbolt and reposition the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement () . Page 12758 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Page 13523 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 20468 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 16808 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 6644 Fuel Injector 5 (Diesel) Page 8475 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 2652 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Page 2748 Fuse Block - I/P X2 (except MEX) Page 6703 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel pressure sensor to the fuel line and tighten the sensor to 15 Nm (11 lb ft) . 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Page 10139 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case High/Low Shift Fork Pad 11 - Transfer Case High/Low Shift Fork 12 - Transfer Case High/Low Shift Fork Spring Assembly 13 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 14 - Transfer Case Two/Four Wheel Drive Actuator Cam Spacer 15 - Transfer Case Two/Four Wheel Drive Actuator Cam 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case High/Low Shift Fork Pin 18 - Transfer Case Actuator Shaft Gear 19 - Transfer Case Rear Output Shaft Assembly 20 - Transfer Case Front Output Shaft Drive Chain Assembly 21 - Transfer Case Front Output Shaft Drive Sprocket 22 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly Page 7293 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 19616 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 18208 Memory Seat Module (MSM) X3 (AN3) Interior - Lint Accumulation On Ebony Colored Seats Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 15555 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab with 10 Series with ASF) Page 15262 Page 19351 Page 13273 Page 6240 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 1018 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 7375 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 13710 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Page 19170 3. Position the tie down loop. 4. Plug weld accordingly. 5. Clean and prepare all welded surfaces. 6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair () . 7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems) . Page 18065 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 11520 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 763 Page 15509 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Specifications Axle Nut: Specifications Hub Nut ............................................................................................................................................... ..................................................... 240 Nm (177 lb ft) Page 14007 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 381 Trailer Brake Control Module (JL1 with 31 Series) Page 12417 Page 12053 Fuse Block - I/P X4 Page 2242 Note Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Page 6848 Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Cluster Schematics) * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 4. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 5. Connect a test lamp between the control circuit and the ignition circuit. 6. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 7. If all circuits test normal, replace the IPC. Page 7559 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 18939 Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with A68) Rear Seat Latch Replacement (Extended Cab with A68) Page 10328 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 6762 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 19. Install the fuel fill cap. 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 11700 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 3027 Fuse Block - Auxiliary X1 (HP2) Page 7039 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Page 13979 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 7319 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 14956 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Top of the Headliner Components (Regular Cab) Page 13423 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 7497 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 13755 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 10817 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Page 7381 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Body Controls - Unable To Reprogram Body Control Module Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: 09-01-39-004A - END OF INFORMATION NEED Control Module HVAC: Technical Service Bulletins 09-01-39-004A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-01-39-004A Date: October 29, 2009 Subject: EI09086 - Automatic HVAC Inoperative, Automatic HVAC Control Replacement or Reprogramming (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK All Equipped with Automatic HVAC (RPO CJ2) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-01-39-004 (Section 01 - HVAC). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 20603 Window Switch - Right Rear (Crew Cab with A31/Extended Cab with ABV) Page 5316 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. If replacing the right side spark plug wire(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug wire(s) through the wheel opening. 2. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 3. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Page 1774 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 8080 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Locations Fuel Pressure Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 1602 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 15383 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Page 10427 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 13811 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (4.8L/5.3L/6.0L/6.2L) Page 15242 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Rear of the Engine Compartment Components A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 20079 Page 18296 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Crew Cab) Sunroof Sunshade Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair )Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 2. Remove the screws (1) that retain the water trough to the sunroof frame 3. Remove the water trough through the roof opening of the vehicle. 4. It is only necessary to lower the headliner. Only do those steps in the headliner replacement procedure that will lower the headline enough to gain access to the part to be remove. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 5. Remove the left and right sunroof housing drain gutters (1) from the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Slide the sunshade (3) rearward to release it from the tracks. 7. Remove the sunshade from the of the vehicle. Installation Procedure Page 15552 Page 8542 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 12432 Junction Block - Left I/P X1 (except MEX) Page 13220 Page 17559 Rear Door Window Motor: Service and Repair Rear Sliding Window Module Replacement Rear Sliding Window Module Replacement Removal Procedure Note The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. Restraint System - Normal Safety Belt Locking Conditions Seat Belt: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 2259 Fuel System Diagnosis (W/FPCM) Fuel System Diagnosis (w/FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Important: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Ignition OFF, all accessories OFF, install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . Diagrams Power Distribution Module: Diagrams Component Connector End Views Accessory DC Power Control Module X1 (HP2) Accessory DC Power Control Module X2 (HP2) Page 8638 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 4534 Note The sight shield mounting fastener must be installed and tightened. Failure to properly tighten the sight shield mounting fastener may result in an open High Voltage Interlock Circuit (HVIC) condition and DTCs. 1. Install the sight shield onto the ball studs (2) and tighten the sight shield mounting fastener (1). Tighten the fastener to 5 Nm (44 lb in) . 2. Install the fender brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 3. Enable high voltage. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 1547 Fuel Pump and Sender Assembly - Rear (LY6 with MEX without NQZ) Page 20595 Door Lock/Window Switch - Passenger X4 (AN3) Page 12186 Fuse Block - I/P X3 Locations Drive Motor Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 15356 Page 10675 Acceleration/Deceleration Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) Page 20680 For vehicles repaired under warranty, use the table. Disclaimer Page 8264 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 13043 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 5964 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Page 12245 Page 1781 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 19875 For vehicles repaired under warranty, use the table. Disclaimer Page 16752 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 7869 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 5661 Page 13026 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12597 Page 4723 Drive Motor Generator Battery Control Module X3 (HP2) Page 2869 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Page 12458 Junction Block - Rear Lamps X2 Page 10723 6. Remove all dirt and debris from the electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV). 7. Disconnect the EBCM electrical connector. 8. Loosen, but do not remove, the EBCM bolts (1). Note Do not pry the EBCM from the BPMV. The EBCM must be pulled away from the BPMV evenly. 9. Using the loosened EBCM bolts as a guide, carefully pull the EBCM (1) evenly away from the BPMV to release the electrical connectors. Page 6765 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (2). 16. Remove the fuel/EVAP line clip nut (1). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Page 8738 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 6158 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 8012 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case Two/Four Wheel Drive Actuator Cam 15 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 16 - Transfer Case High/Low Shift Fork 17 - Transfer Case High/Low Shift Fork Pads 18 - Transfer Case High/Low Shift Fork Spring Assembly 19 - Transfer Case High/Low Shift Fork Pin 20 Transfer Case Control Actuator Shaft 21 - Transfer Case Rear Output Shaft 22 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 23 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 24 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 25 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring 26 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring 27 - Transfer Case Front Output Shaft Drive Chain Assembly 28 - Transfer Case Front Output Shaft Drive Sprocket 29 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 30 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 31 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 32 Transfer Case Oil Pump Assembly 33 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 34 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 35 - Transfer Case Rear Output Shaft Rear Bearing Assembly 36 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 37 - Transfer Case Oil Pump Suction Pipe Seal 38 - Transfer Case Oil Pump Suction Pipe 39 - Transfer Case Front Output Shaft Rear Bearing Assembly 40 - Transfer Case Front Output Shaft Driven Sprocket Spacer 41 - Transfer Case Front Output Shaft Driven Sprocket 42 - Transfer Case Front Output Shaft Hole Plug 43 - Transfer Case Front Output Shaft 44 Transfer Case Front Output Shaft Front Bearing Assembly Page 2204 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 20806 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 18675 Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Page 8802 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 17846 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 20419 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 7296 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 14873 Air Door Actuator / Motor: Diagrams Component Connector End Views Recirculation Actuator (C67/CJ2) Mode Actuator (C67/C42/CJ2) Page 1432 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 1759 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 370 Seat Climate Control Module X2 (KB6) Page 12579 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 4687 7. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 8. Rotate the drive motor generator control module assembly onto the PIM cover. 9. Remove the APM to PIM mounting fasteners (1). 10. Remove the APM (2) and discard the coolant seal (3). 11. Remove the drive motor generator power inverter coolant pipe bolts (4, 7). 12. Remove the drive motor generator power inverter coolant pipes (5, 8). 13. Remove and discard coolant seals (6, 9). Installation Procedure Page 1232 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1681 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 13268 Page 1728 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 8979 Page 19583 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 10958 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH7) Rear Brake Rotor Replacement (JH7) Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Caution: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 4. Remove the hub and rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement) . 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. 8. Separate the hub from the rotor. Installation Procedure 1. Align the hub and the rotor. Page 16931 Page 14988 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 15257 Page 13190 Fuse Block - Underhood Bottom View Page 19599 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 8031 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Page 18743 Page 1405 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Body - Tubular Assist Step Service Parts Cpomponents Auxiliary Step / Running Board: Technical Service Bulletins Body - Tubular Assist Step Service Parts Cpomponents INFORMATION Bulletin No.: 09-08-61-001A Date: October 21, 2009 Subject: Information on Tubular Assist Step Service Part Component Availability Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to add the 3" round service components. Please discard Corporate Bulletin Number 09-08-61-001 (Section 08 - Body and Accessories). Service Component Availability Some dealers have submitted warranty claims against and replaced entire tubular assist step packages for customer concerns that only require the replacement of a serviced component. Dealers may not have been aware that the components of the tubular assist step packages, such as brackets, end caps, step pads and mounting hardware are available as service parts. This information is in the chart below. Instructions If the condition can be corrected with a component replacement instead of replacing the tubular assist step packages, order the component only. Use the attached parts information to order the components. The parts are in Group 21.506B in the Service Parts Catalog. Page 13619 Page 20583 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 17942 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Page 14723 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 12350 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 14660 Frequently Asked Questions Disclaimer Front Seat Cushion Center Cover Replacement Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Page 5412 Body Control Module (BCM) X6 Page 1506 Drive Motor Temperature Sensor: Diagrams Component Connector End Views Generator Control Module Temperature Sensor (HP2) Generator Battery Vent Fan (HP2) Page 10952 Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JH6, JH7) Front Brake Rotor Replacement (JH6, JH7) MP 1222/1225/1226-NQG - Transfer Case Transfer Case Actuator: Locations MP 1222/1225/1226-NQG - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 6668 19. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 20. Install the CPA retainer. 21. Connect the engine wiring harness electrical connector (2) to the electronic throttle control. 22. Connect the engine wiring harness electrical connectors (5) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 23. Install the engine wiring harness clip (4) to the ignition coil bracket stud. 24. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 25. Install the CPA retainer (2). 26. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. Page 6740 27. Remove the fuel injectors (3) from the fuel rail. 28. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4). Installation Procedure 1. Lubricate the NEW fuel injector O-ring seals with clean engine oil. 2. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors. 3. Install the fuel injectors (3) into the fuel rails. 4. Install the fuel injector retainers (1). 5. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil. 6. Position the fuel rail onto the intake manifold. 7. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Frame Front Crossmember Replacement Cross-Member: Service and Repair Frame Front Crossmember Replacement Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 18884 * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 17. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower motor control circuit terminal 2 * Seat cushion blower motor speed control terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 18. If all circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. Passenger Heated/Cool Seat Inoperative 1. Ignition OFF, disconnect the X1, X2, X3 harness connectors at the CCSM. 2. Connect a test lamp between the signal circuit terminal 6 X3 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. Note If the resistance is measured with the seat still warm or cool, the resistance values will vary. At 68°F (20°C), the nominal resistance value is 1200 Ω ±5 percent . For warmer or cooler ambient temperatures, refer to the Temperature vs Resistance table below. The delta resistance values between the seat cushion and seat back temperature sensors should not be greater than 2000 Ω. 4. Ignition OFF, test for 300 Ω - 18 kΩ between the signal and low reference circuits listed below: * Seat cushion temperature sensor signal circuit terminal 2 X2 and low reference circuit terminal 3 X2. * Seat back temperature sensor signal circuit terminal 4 X2 and low reference circuit terminal 5 X2. ‹› If less than the specified range, test for a short between the signal and low reference circuits. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. ‹› If greater than the specified range, test the signal and low reference circuits for a short to voltage or an open/high resistance. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. Note The test leads must be connected in the correct polarity, otherwise lower out of range values will appear. Use the Positive Lead for the COOL control circuit and the Negative Lead for the HEAT control circuit. If the resistance is measured with the seat still warm or cool, the resistance values will vary even if the system was powered up for just a few seconds. The TED must be allowed to stabilize to room temperature prior to a measurement. The conditions listed below will change the resistance to out of range values: * The test leads are incorrectly connected. * Air blowing across the TED * Measuring the resistance at other than room temperature of 70°F (21°C) * Holding the TED portion of the heat/cool seat ventilation blower in your hand Heated/Cooled Seats Inoperative-(Split For Indexing)-Part 3 Page 20190 Page 18893 Page 10539 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10275 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 9673 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 18035 9. Remove the scan tool. 10. Exit the vehicle. Operate all functions on transmitters to verify correct system operation. Page 6884 Page 17951 Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Page 6816 Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire. Page 6586 * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 6859 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 4623 Drive Motor Generator Battery Control Module X5 (HP2) Page 7773 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5432 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 13973 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 14172 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Page 546 Page 18099 Memory Seat Module (MSM) X6 (AN3) Page 13226 Junction Block - Left I/P X5 (SPO Alarm) Page 230 Page 13842 X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X224 Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 13414 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 15289 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 19006 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 4L60-E / 4L65-E / 4L70-E Automatic Transmission Pan Removal ...................................................... ................................................................................................................................... 4.7 liters (5.0 quarts) Overhaul .................................................................................................................................. ......................................................... 10.6 liters (11.0 quarts) 300 mm Torque Converter Approximate Dry Fill ............................................................................................................................ ................................................................ 11.50 liters (12.1 quarts) 6L80 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 5.7 liters (6.0 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 6L90 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 6.0 liters (6.3 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 2ML70 AUTOMATIC TRANSMISSION Drain Plug Only ..................................................................... ........................................................................................................... 9.93 liters (10.5 quarts) Drop Pan and Filter ...................................................................................................................................... ................................... 10.88 liters (11.5 quarts) Dry Transmission (Empty) .............................................................................................................................................................. 12.30 liters (13.0 quarts) Page 5508 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 13556 Junction Block - Left I/P X7 (JF4) Page 16260 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 2872 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Page 11951 Auxiliary Power Outlet: Tools and Equipment Special Tools Page 13069 Page 10132 Transfer Case Actuator: Locations MP 1625/1626-NQF - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 - Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor - O-Ring - Seal 15 - Transfer Case Rear Half 16 Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 22 - Transfer Case Two/Four Wheel Drive Actuator Assembly 23 - Transfer Case Two/Four Wheel Drive Actuator Seal Page 8678 Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Page 20006 Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Page 10447 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Torque Converter Clutch (TCC) Solenoid Valve (M30) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 2956 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16717 Radio Front Speaker Replacement Radio Front Speaker Replacement Page 10325 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 2523 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Page 7183 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 12063 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 5601 Engine Control Module (ECM) X2 (4.8L/LY6 or 6.2L with Y91) Page 1848 Page 17296 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Special Tools J-41769 - Fuel Line Quick Disconnect Tool Disconnect Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Remove the fuel line retainer. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Using compressed air, blow any dirt or debris from around the connection. 4. Using the correct tool from the J-41769 - tool , insert the tool into the female connector end, then push inward in order to release the quick connect locking tabs. Page 330 Page 5271 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 18221 Page 2913 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 9720 Page 15460 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 5167 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 9940 Case Adapter: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Adapter Replacement Page 8821 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 20868 Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. "An unattended (vehicle parked - key not in the "ON" position) under hood fire that can occur at any time and possibly involve nearby vehicles or structures." If the customer still refuses, provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record "customer declined recall repair" on the repair order and, if possible, have the customer sign the repair order. Retain this repair order at the dealership. Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Page 2152 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 18755 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9418 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft) . 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with the two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 9. Remove the support and lower the vehicle. Page 6772 8. Remove the fuel pipe bracket nut from the bellhousing stud. 9. Remove the fuel line clip (1) from the bracket on the automatic transmission. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 16453 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 13514 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12651 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Console Harness (Y91/UQA/D07) Page 8746 Harness Components Page 17877 Disclaimer Page 4468 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 12023 Page 11300 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 13582 Page 12295 Page 10759 1 - Wheel Speed Sensor (WSS) -Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) -Left Front (JL4/JF3/JF7/JH6/JH7) Front Frame and Underbody Components - 2 of 2 Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 2224 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 4864 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 13725 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Page 6687 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 5663 Switches and Relays Page 18780 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 19570 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6804 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 4529 Drive Motor Control Module: Description and Operation Drive Motor Generator Control Module Description and Operation Overview The drive motor generator power inverter module (PIM) assembly converts high voltage direct current (DC) electrical energy to 3 phase alternating current (AC) electrical energy. The accessory DC power control module (APM) converts high voltage DC electric energy into low voltage (14V) and intermediate voltage (42V) in order to charge the vehicles accessory battery and supply electric energy to the 42V power steering system. The APM and PIM are fastened together and are referred to as the drive motor generator control module assembly. The drive motor generator control module assembly is cooled with pre-mixed Dexcool(R) circulating through a cooling system that is separate from the engine cooling system. The hybrid cooling system utilizes a heat exchanger at the front of the vehicle and electric pumps to circulate the coolant. The engine control module (ECM) monitors a temperature sensor in the hybrid cooling system and operates the radiator fan and the hybrid coolant pumps in response to system temperature. High Voltage Circuits Direct Current (DC) The drive motor generator control module assembly is connected to each pole of the high voltage (HV), direct current (DC) drive motor generator battery. Both of the negative and positive HV DC battery poles are isolated from the vehicle chassis by a specific amount of resistance. Each HV DC cable is switched ON or OFF by a high voltage, high current contactor relay contained within the drive motor generator battery assembly. All HV DC negative and positive DC cables are individually shielded and orange in color to alert the technician to the potential presence of high voltage. The electric air conditioning compressor high voltage DC cables are externally connected at the drive motor generator control module assembly. The APM and PIM share an internal connection that supplies the APM with high voltage DC current. Three Phase Alternating Current (AC) Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician to the potential presence of high voltage. Intermediate and Low Voltage Circuits The APM converts high voltage 300V DC current into both intermediate voltage, 42V, and low voltage, 12V, current. Intermediate Voltage 42V Direct Current Intermediate voltage 42V cables are individually shielded and are blue in color to alert the technician to the potential presence of intermediate voltage. Low Voltage (12V) Direct Current Low voltage (12V) cables on the hybrid-electric vehicle do not require unique coloring or servicing procedures. Drive Motor Generator Power Inverter Module (PIM) Assembly Overview Contained within the PIM assembly are the hybrid powertrain control module (HPCM), and two motor control modules (MCM). Each MCM controls its respective motor generator. All three modules are flash-programmable micro-processors. Hybrid Powertrain Control Module (HPCM) Location The HPCM is a non-serviceable, flash-programmable micro-processor contained within the PIM assembly. Operating Functions The HPCM is the main controller of hybrid operation. The HPCM determines when to perform hybrid operation modes such as engine Auto-stop and regenerative braking. The HPCM also operates in conjunction with the battery energy control module (BECM) to determine when to enable and disable the DC high voltage circuits. Each MCM operates the applicable electric motor generator based upon HPCM commands. Communication and Hosted Diagnostics The HPCM is the host controller for diagnostic trouble code (DTC) information for the following control modules: Page 1734 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 10981 9. Remove the brake shoe return spring. 10. Compress the park brake cable spring, disengage the park brake cable fitting end from the park brake lever and remove the secondary brake shoe (1). 11. Clean the backing plate and apply high temperature brake lubricant to the brake shoe contact surfaces of the rear brake backing plate. 12. Inspect and replace any missing, worn, or damaged drum brake hardware. Refer to Drum Brake Hardware Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Drum Brake Hardware Inspection) . Installation Procedure Page 2954 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 17483 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Extended Cab) Rear Side Door Outside Handle Replacement (Extended Cab) Page 5103 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9053 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 6663 24. Remove the fuel rail bolts. Caution: * Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. * Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages. Note Before removal, clean the fuel rail with a spray type engine cleaner, such as GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent. Note Lift evenly on both sides of the fuel rail until all injectors are removed from their bores. 25. Remove the fuel rail assembly. Page 10356 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 3677 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Page 12409 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 8990 Page 18672 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Page 6574 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 6082 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 2884 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 18832 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 12236 Junction Block - Left I/P X9 (except MEX) Page 5777 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7056 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 3005 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11755 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 19512 Page 12463 Page 6753 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 19. Install the fuel fill cap. 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 825 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10410 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 10351 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 6049 Page 20558 Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 482 Page 2926 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 5157 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 4. Remove the HO2S (3). Installation Procedure Page 11640 Page 5756 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 12556 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 10476 23 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 24 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 25 - Transfer Case Oil Pump Assembly 26 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 27 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 28 - Transfer Case Rear Output Shaft Rear Bearing Assembly 29 Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 30 - Transfer Case Oil Pump Suction Pipe Seal 31 - Transfer Case Oil Pump Suction Pipe 32 - Transfer Case Front Output Shaft Rear Bearing Assembly 33 - Transfer Case Front Output Shaft Driven Sprocket Spacer 34 Transfer Case Front Output Shaft Driven Sprocket 35 - Transfer Case Front Output Shaft Hole Plug 36 - Transfer Case Front Output Shaft 37 - Transfer Case Front Output Shaft Front Bearing Assembly Clutch Components Page 7877 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 1433 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) Page 7263 Page 9277 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Page 7230 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 2670 Fuse Block - Mobile Radio (9L4) Page 9507 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Page 8745 Module Circuit Function Icons Page 13787 Brakes - Front Brake Induced Pulsation/Vibration Brake Rotor/Disc: Customer Interest Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Page 3846 20. Remove the air conditioning (A/C) compressor bracket bolts (1). 21. Remove the oil pan bolts. 22. Remove the oil pan. 23. If reusing the oil pan perform the following steps, otherwise proceed to step 3 of the installation procedure. Note DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. 24. Drill out the oil pan gasket rivets (2), if necessary. 25. Remove the oil pan gasket (1) from the pan. 26. Discard the oil pan gasket. 27. Discard the rivets, if necessary. Page 20923 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Page 2785 Page 10548 Director, Customer and Relationship Services 09241 Page 5727 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4239 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 11048 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Page 17509 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Page 15322 HVAC Control Module X2 (CJ2) Page 13791 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Page 13389 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Page 8684 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Page 5938 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 12748 Page 6266 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 8097 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 9701 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 11740 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 20518 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15321 Control Module HVAC: Diagrams HVAC Control Module Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67/C42/MEX) Page 16433 Non-Validated Apple Device Specifications Page 20807 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 8249 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4688 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in ). Note Only use pre-mixed DEX-COOL(R) on the coolant pipe O-ring to aid in tube installation. 4. Lubricate the new seals (6, 9) with pre-mixed DEX-COOL(R). 5. Install new seals (6, 9) onto the drive motor generator power inverter coolant pipes (5, 8). 6. Install the coolant pipes (5, 8) to the PIM assembly with bolts (4, 7). Tighten the fasteners to 5 Nm (44 lb in) . 7. Rotate the drive motor generator control module assembly onto the APM. 8. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 9. Plug the remaining coolant pipe with the GE-48494 - adapter kit plug and clamp (1). Page 18959 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 11090 20. Slide the EBCM/BPMV and bracket assembly (1) toward the center of the vehicle and remove the assembly from the vehicle frame. 21. Place the EBCM/BPMV and bracket assembly on a clean work surface. 22. Remove the BPMV bolts (1). Page 6169 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8160 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 11669 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 2988 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 959 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 8749 Component Parts Page 19697 Fuel Gauge Sender: Diagrams Component Connector End Views Fuel Pump (Diesel with 31 Series without NQZ) Fuel Pump and Sender Assembly - Front (Gas Except MEX) Page 17111 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 19399 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 13434 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 1782 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 18851 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 19372 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 14343 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 10272 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 20492 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 5488 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 17112 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 15884 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 18833 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 10762 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (Except 10 Series) Page 13542 Fuse Block - Mobile Radio (9L4) MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 2819 Fuse Block - Auxiliary (HP2), Top View Page 17827 Console: Service and Repair Floor Console Bezel Replacement Floor Console Bezel Replacement Page 19569 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 1159 Page 1980 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Page 7441 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 20459 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 2779 Fuse Block - Auxiliary X1 (HP2) Page 8013 Transfer Case Actuator: Locations Powertrain Component Views Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 10411 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement Drive Belt Replacement Removal Procedure 1. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 3. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 4. Remove the belt (1) from the pulleys and the drive belt tensioner (2). 5. Slowly release the tension on the drive belt tensioner. 6. Remove the breaker bar and socket from the drive belt tensioner bolt. 7. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Page 18275 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control relay electrical connector. Note It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Page 12187 Fuse Block - I/P X4 Page 11836 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11679 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 20004 Page 17193 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 19012 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 19474 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 1847 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30/TZ0/MYC or MW7/M99 with NQG/NQF) Vehicle Speed Sensor (VSS) (MW7 Except NQG/NQF) Page 12460 Junction Block - Rear Lamps X4 Page 4752 Component Locations Multiple Junction Connector: Component Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 9475 Note On axles with a locking differential, keep the differential pinion shaft slightly withdrawn. 5. Install the differential pinion gear shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the NEW differential pinion gear shaft bolt and tighten to 34 Nm (25 lb ft) for the 8.6 inch axle and50 Nm (37 lb ft) for the 9.5 inch axle. 7. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) )Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 8. Install the wheel speed sensor. * For Hybrid vehicles, refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . * For non Hybrid vehicles (1500 series), refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . * For non Hybrid vehicles (2500 series), refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . 9. Install the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 10. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Page 6590 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Page 18358 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Extended Cab) Sunroof Window Replacement (Extended Cab) Removal Procedure 1. Position the sunshade panel fully rearward. 2. Position the sunroof window panel to the vent position. 3. Remove the sunroof window panel screws from the sunroof window panel. 4. Remove the sunroof window panel from the sunroof module. Installation Procedure 1. Position the sunroof window panel to the sunroof module. Ensure that the information logo stencil is towards the rear of the sunroof opening. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the sunroof window panel screws to the sunroof window panel. Tighten the sunroof window panel screws to 4 Nm (35 lb in). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments )Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments) . 4. Inspect the sunroof window panel for proper operation. Page 11259 Disclaimer Page 9373 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities andFluid and Lubricant Recommendations in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft) . 4. Lower the vehicle. Page 5717 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5233 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 18274 Locations Parking Brake Release Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 3910 Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Remove the generator. Refer to Generator Replacement (4.3L) ()Generator Replacement (6.6L) ()Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L) () . 3. Remove the engine harness retainer nut (1). 4. Remove the engine harness retainer from the stud and locator pin. 5. Disconnect the engine harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid. 6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor. Page 19424 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 15981 1 - Lower Radiator Support 2 - Inflatable Restraint Front End Sensor Front of Vehicle Components (10 Series) Page 4913 Page 7496 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Page 13024 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 9399 Note Press the bearing on until the cone seats on the pinion. 5. Using the J 24433 - installer and a hydraulic press, install the inner pinion bearing. 6. Install the new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations . 8. Install the outer pinion bearing into the pinion bearing retainer. 9. Using the J 44414 - installer , install the new pinion oil seal. 10. Install the pinion in the pinion gear bearing retainer. 11. Install the drive pinion flange/yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . Note Do not apply sealant to the pinion gear bearing retainer at this time. 12. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth. 13. Install the pinion gear bearing retainer to the axle housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 14. Install the pinion bearing retainer bolts and tighten to 88 Nm (65 lb ft) . Page 13280 Page 13248 Junction Block - Rear Lamps X1 Page 2904 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 6180 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 13509 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 20856 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Page 16715 Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Page 5948 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 9236 9. Install NEW fluid pump seals (6). 10. Install a NEW control valve upper body seal assembly (1). 11. Install the control valve upper body (2). Caution: Bolt torque sequencing is critical to the proper function of the control solenoid valve assembly. Failure to follow the required sequencing may result in transmission malfunction. 12. Install the control valve upper body bolts (3). Tighten the bolts to 11 Nm (97 lb in). 13. Install the manual shift detent spring (5). 14. Install the manual shift detent spring bolt (4). 15. Install the control solenoid valve and transmission control module assembly. Refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement (See: Extension Housing/Service and Repair/Control Solenoid Valve and Transmission Control Module Assembly Replacement) . Page 2711 Page 20348 Turn Signal Switch: Diagrams Component Connector End Views Multifunction Switch - I/P (Except MEX) Turn Signal/Multifunction Switch X1 Page 17500 Door Latch - Passenger Locations Battery Current Sensor: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 7907 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 14977 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 11631 Switch Position Icons Locations Impact Sensor: Locations Door Component Views Right Rear Door Components (Extended Cab) 1 - Window Switch -Right Rear (ABV) 2 - Window Motor -Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 4 - Speaker -Right Rear Right Rear Door Components (Crew Cab) Page 18881 are variable resistors, their resistance changes as the temperature of the seat changes. Then based on the seat temperature, the CCSM controls the voltage level that it applies to the TEDs and blower motors. Diagnostic Aids The following conditions must be met in order to perform valid tests when diagnosing the climate control seat system: * The ignition must be cycled OFF then ON between each test in order to reset the CCSM. * Most circuit faults will set a DTC within 1.5 minutes. However, some circuit faults may cause a performance problem in one mode and be inoperative and set a DTC in another mode. In some cases it may take 5 minutes or more for a DTC to set. Operate the heated/cooled seat in each of the three modes for 5 minutes or more then check for DTCs. * The engine must be running in order to supply the CCSM with the amount of current needed to operate the heated/cool seat system. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated/Cooled Seats Description and Operation (See: Description and Operation/Heated/Cooled Seats Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. If both, the driver and passenger heated and cooled seats are inoperative, refer to Driver and Passenger Heated/Cool Seats Inoperative. 2. Ignition ON, observe the scan tool Driver Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the driver door lock/window switch. 3. Observe the scan tool Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the front passenger door lock/window switch. 4. If all heated and cooled seat functions operate normal, but the heated/cooled seat switch indicators do not illuminate or are always ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the appropriate door lock/window switch. Circuit/System Testing Driver and Passenger Heated/Cool Seats Inoperative 1. Ignition OFF, disconnect the X1 harness connector at the CCSM. 2. Verify that a test lamp illuminates between the ground circuit terminal M and B+. Page 11890 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 3292 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Page 12750 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) Page 16220 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 13515 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7842 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 15797 Seat Belt Buckle: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 11143 Remove the ignition key. 4. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 5. Remove the master cylinder nuts (1). Discard the master cylinder nuts. 6. Without disconnecting the brake pipes, release and carefully position aside the master cylinder (1). Support the master cylinder with heavy mechanics wire or equivalent. Page 17159 Page 464 Page 16380 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Specifications Connecting Rod: Specifications Connecting Rod Connecting Rod Bearing Clearance Production............................................................................................................0.023-0.065 mm (0.0009-0.0025 in) Connecting Rod Bearing Clearance Service....................................................................................................................0.023-0.076 mm (0.0009-0.003 in) Connecting Rod Bore Diameter - Bearing End................................................................................................................56.505-56.525 mm (2.224-2.225 in) Connecting Rod Bore Out-of-Round - Bearing End Production.................................................................................0.004-0.008 mm (0.00015-0.0003 in) Connecting Rod Bore Out-of-Round - Bearing End Service.......................................................................................0.004-0.008 mm (0.00015-0.0003 in) Connecting Rod Side Clearance.......................................................................................................... ..................................0.11-0.51 mm (0.00433-0.02 in) Connecting Rod Bolts - First Pass.................. .................................................................................................................................................20 Nm (15 lb ft) Connecting Rod Bolts - Final Pass......................................................................................... ..................................................................................85 degrees Page 4081 Compression Check: Testing and Inspection Engine Compression Test Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. Note When performing an engine cylinder compression test for the RPO-LFA engine, note that this engine has a camshaft position actuator with a late intake valve closing feature and a 29 degree retard park position. With the actuator parked in a retard position, the effective compression of the engine is reduced during cranking. Compression values on the gage will be lower than a typical small block engine that does not have this feature. 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition key in the OFF position. 3. Charge the battery if the battery is not fully charged. 4. Disable the fuel and spark by removing the Fuel Pump relay and Powertrain relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) for the Fuse Block - Underhood Label. 5. Remove the spark plug wires from the spark plugs. 6. Remove all of the spark plugs. Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. 7. Install a compression gage to the cylinder to be tested. 8. Start with the compression gage at zero and crank the engine 3-5 seconds using the ignition key. 9. Return the ignition key to the OFF position. 10. Measure the compression for each cylinder. Record the readings. 11. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any 1 cylinder is 862 kPa (125 psi), the lowest allowable pressure for any other cylinder would be 607 kPa (88 psi). (862 kPa x 70% = 607 kPa) (125 psi x 70% = 88 psi). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. 12. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 13. Reinstall the Fuel Pump relay and Powertrain relay. 14. Using the scan tool, clear all diagnostic codes. Page 19437 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 1648 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 7172 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 20411 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 4800 Auxiliary Body Control Module (XBCM) X2 (EXP) Page 7910 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 11215 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 11713 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11351 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 19812 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 316 Memory Seat Module (MSM) X4 (AN3) Page 14829 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 11651 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Component Locations Auxiliary Battery Relay: Component Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 7105 Switch Position Icons Page 19523 Page 11020 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Page 6775 11. If equipped with 4WD, install the fuel hose/pipe clip (1) to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft) . 14. Position and install the BPMV. Refer to Brake Pressure Modulator Valve Replacement () . 15. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 16. Lower the vehicle. Page 9314 Actuator: Locations Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle (9.25 inch) Front Drive Axle (9.25 inch) 1 - Front Drive Axle Inner Shaft 2 - Front Drive Axle Inner Shaft Seal 3 - Front Drive Axle Inner Axle Shaft Bearing 4 - Front Drive Axle Inner Shaft Housing 5 - Front Drive Axle Clutch Gear Thrust Washer 6 - Front Drive Axle Clutch Gear 7 - Front Drive Axle Inner Shaft Retaining Ring 8 - Front Drive Axle Clutch Sleeve 9 - Front Drive Axle Clutch Shim 10 - Front Drive Axle Actuator 11 - Front Drive Axle Inner Shaft Housing Bolt 12 - Front Drive Axle Clutch Fork Assembly 13 - Front Drive Axle Clutch Fork Inner Spring 14 - Front Drive Axle Clutch Shaft Bearing 15 - Front Drive Axle Clutch Shaft 16 - Front Differential Carrier Bolt 17 - Front Differential Carrier 18 - Front Differential Carrier Half Location Pin 19 - Front Differential Case Bearing 20 - Front Differential Bearing Adjuster Nut 21 - Front Differential Bearing Adjuster Nut Sleeve 22 - Front Differential Side Bearing Cup 23 - Differential Ring Gear Bolt 24 - Front Differential Side Bearing 25 - Front Differential Pinion Gear Shaft Page 9782 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 12342 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 19468 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 13732 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Page 5773 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8230 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Drivetrain - Clunk Noise At A Stop Or From Launch Slip Yoke: All Technical Service Bulletins Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 20880 All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Daily Rental (Avis, Budget, Enterprise, etc.) Issue check to the daily rental company if valid proof of vehicle ownership documentation is available. Confirm local address and mail or provide check to their representative at vehicle pickup. All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Lease Management Company (PH&H;, GE Capital, ARI, etc.) Issue check to the lease management company if valid proof of ownership documentation is available. Ask the customer where the check should be mailed. Approximately 7,500 vehicles are involved and these customers will be receiving a letter from their lease management company explaining this situation. All checks must include the complete 17 character Vehicle Identification Number. Q12. What should I do if a customer refuses to have the recall service procedure performed on his/her vehicle? A12. If a customer initially declines the recall repair, please make sure that he/she fully understands the possible consequences. Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (HWFS). As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10153. - Schedule an appointment with your GM dealer/retailer. - This service will be performed for you at no charge. Why is your vehicle being recalled? A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. What will we do? Your GM dealer/retailer will permanently disable and remove the heated washer fluid system. In addition, because the heated washer feature will be disabled, the dealer will provide a customer satisfaction payment of $100 to the customer. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer/retailer will need your vehicle longer than the actual service correction time of approximately 20 minutes. An updated page for your Owner Manual will be provided and inserted at the time of service to document that the feature has been permanently disabled and removed from your vehicle. If your vehicle is within the New Vehicle Limited Warranty, your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? You should contact your GM dealer/retailer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition repaired in the past, you will still need to take your vehicle to your dealer/retailer for this recall. Page 11069 Front Brake Hose Replacement Front Brake Hose Replacement (JH6, JH7) Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 5617 4. Disengage the bracket retainer tabs (1) securing the ECM to the bracket. 5. Remove the ECM (3) from the bracket. Installation Procedure 1. Set the bottom of ECM into the ECM bracket tab (2). 2. Push the ECM (3) in securing the ECM to the bracket. Page 1456 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Page 2857 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 20540 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Page 9600 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8725 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 14217 7. Install the runout gauge at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the runout gauge and pull outward in order to take a reading. 9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud. If the movement is more than 1 mm (0.039 in) then replace the idler arm. Page 4872 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 6388 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 12505 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 7283 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 470 Page 4722 Drive Motor Generator Battery Control Module X2 (HP2) Page 12983 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 329 Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 1361 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Page 7981 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 12959 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2740 Junction Block - Rear Lamps X3 Caster Description Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear . Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 18896 Page 8424 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18739 Page 8086 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 11041 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Voice Recognition System - Won't Recognize Bluetooth(R) Steering Mounted Controls Communication Module: Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Page 1472 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Front of Vehicle Components (10 Series) Page 5811 Page 5430 Camshaft Position (CMP) Sensor (Diesel) Page 3493 1. Place the service gasket (1) onto the valve lifter oil manifold. 2. Install the valve lifter oil manifold (1) to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the valve lifter oil manifold bolts (2). Tighten the bolts to 25 Nm (18 lb ft). 4. Connect the engine harness electrical connector (1) to the oil pressure sensor. 5. Install the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair) . Page 3583 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 11097 9. Connect the right supply brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . 10. Connect the left supply brake pipe fitting (2) and tighten to 18 Nm (13 lb ft) . 11. Connect the primary brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 6560 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 14321 Steering Control Module: Service and Repair Electronic Power Steering Motor Control Module Replacement Page 16436 Auxiliary Input / Output Jack: Locations Instrument Panel/Center Console Component Views Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 695 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 15340 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Page 6430 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 12937 Component Parts Page 13932 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 7338 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 2898 Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 3036 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 8387 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Locations Acceleration/Deceleration Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 13017 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 5149 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 6. Remove the HO2S (1). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 728 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (4.3L) Page 11817 Page 1004 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 2091 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair) . Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 14274 and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . 13. Perform the power steering control module setup procedure. Refer to Power Steering Control Module Programming and Setup (See: Testing and Inspection/Programming and Relearning) . Page 10134 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case Two/Four Wheel Drive Actuator Cam 15 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 16 - Transfer Case High/Low Shift Fork 17 - Transfer Case High/Low Shift Fork Pads 18 - Transfer Case High/Low Shift Fork Spring Assembly 19 - Transfer Case High/Low Shift Fork Pin 20 Transfer Case Control Actuator Shaft 21 - Transfer Case Rear Output Shaft 22 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 23 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 24 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 25 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring 26 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring 27 - Transfer Case Front Output Shaft Drive Chain Assembly 28 - Transfer Case Front Output Shaft Drive Sprocket 29 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 30 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 31 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 32 Transfer Case Oil Pump Assembly 33 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 34 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 35 - Transfer Case Rear Output Shaft Rear Bearing Assembly 36 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 37 - Transfer Case Oil Pump Suction Pipe Seal 38 - Transfer Case Oil Pump Suction Pipe 39 - Transfer Case Front Output Shaft Rear Bearing Assembly 40 - Transfer Case Front Output Shaft Driven Sprocket Spacer 41 - Transfer Case Front Output Shaft Driven Sprocket 42 - Transfer Case Front Output Shaft Hole Plug 43 - Transfer Case Front Output Shaft 44 Transfer Case Front Output Shaft Front Bearing Assembly Page 14395 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Actuator: Locations Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) 1 - Output Shaft 2 - Pinion Bearing Spacer 3 - Pinion Head Bearing Assembly 4 - Pinion Shim 5 Stem Pinion 6 - Pinion Flange Nut 7 - Pinion Flange Washer 8 - Pinion Flange Assembly 9 - Pinion Seal 10 - Pinion Tail Bearing Assembly 11 - Carrier Housing 12 - Output Shaft Seal Assembly 13 Output Shaft 14 - Drain Plug Assembly 15 - Drain Plug Washer 16 - Fill Plug Assembly 17 - Fill Plug O-ring Seal 18 - Carrier Locator Pin 19 - Vent Connector 20 - Differential Case 21 - Ring Gear 22 - Output Shaft Bearing Assembly 23 - 8-Point Lock Ring 24 - Sleeve and Insert Assembly 25 Differential Side Bearing Assembly 26 - Differential Cross Pin Lock Page 12961 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13810 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.8L and 5.3L) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (6.0L and 6.2L) Page 3462 Camshaft: Service and Repair Camshaft Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure Note If camshaft replacement is required, the valve lifters must also be replaced. 1. Remove the radiator support. Refer to Radiator Support Replacement () . 2. Remove the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair) . 3. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 4. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Page 4020 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass and additional 90 degrees using J 45059 . 9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . Page 19379 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 562 Page 9050 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 5110 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Locations Data Link Connector: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Locations Radiator Cooling Fan Resistor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 9976 Transfer Case Shift Control Module X3 (NQF/NQH) Page 5882 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 16314 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 3065 Junction Block - Rear Lamps X3 Page 1317 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Page 9560 14 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 15 - Propeller Shaft Tube 16 Propeller Shaft Universal Joint 17 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 18 - Propeller Shaft Slip Yoke 19 - Propeller Shaft Slip Yoke Boot Clamp 20 - Propeller Shaft Slip Yoke Boot 21 - Propeller Shaft Slip Yoke Boot Clamp Page 17234 Body Control Module (BCM) X4 Page 7710 Switch Position Icons Page 3202 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 12714 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Interior - Lint Accumulation On Ebony Colored Seats Seat Cover: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 16754 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 12098 Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Fuse Holder X4 (Engine Chassis Harness) (Diesel) Page 10186 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 7904 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13621 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 10025 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 9566 Shudder on Acceleration at Low Speed Shudder on Acceleration at Low Speed Squeak Noise Squeak Noise Universal Joint Noise Universal Joint Noise Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 20250 Page 20007 MP 1222/1225/1226-NQG - Transfer Case Transfer Case Actuator: Locations MP 1222/1225/1226-NQG - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 16720 Rear Pillar Speaker Replacement Rear Pillar Speaker Replacement Page 18496 Seat Adjuster Motor Assembly - Driver X1 (AN3) Component Locations Seat Occupant Sensor: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 6688 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 12255 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 16775 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 18965 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Page 12158 Fuse Block - Underhood X2 Page 10931 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 13838 X209 Inline Harness Connector End Views X209 Chassis Harness to Rearview Camera Jumper Harness (SVA) Page 11653 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Power and Ground Distribution/Diagrams/Electrical Diagrams/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Power and Ground Distribution/Diagrams/Electrical Diagrams/Ground Distribution Schematics) . 08-08-49-016C - END OF INFORMATION NEED Fuel Gauge Sender: Technical Service Bulletins 08-08-49-016C - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 08-08-49-016C Date: May 21, 2009 Subject: EI08347 - DTC P0463, Fuel Gauge/Gage Inaccurately Reads Empty, Low Fuel Light On (Diagnose and Repair Using SI) Models: 2008-2009 Buick Lucerne 2008-2009 Chevrolet Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 08-08-49-016B (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. This bulletin is being revised to end the need for dealer feedback. If you encounter a vehicle with this concern, please diagnose and repair using the information found in SI. Disclaimer Page 12607 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (4.8L/5.3L/6.0L/6.2L) Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 10474 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor O-Ring - Seal 15 - Transfer Case Rear Half 16 - Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Actuator Shaft Position Sensor Bolt/Screw 22 - Transfer Case Actuator Shaft Position Sensor Assembly 23 - Transfer Case Actuator Shaft Position Sensor - O-Ring - Seal 24 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 25 - Transfer Case Two/Four Wheel Drive Actuator Assembly 26 - Transfer Case Two/Four Wheel Drive Actuator Seal 27 - Transfer Case Oil Drain Plug 28 - Transfer Case Oil Fill Plug 29 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 30 Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Internal Components Page 15006 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 10362 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2969 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 50 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 8239 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2773 Fuse Block - Underhood X6 Page 9439 Note DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Restraints - Air Bag Readiness Light On. Malfunction Lamp / Indicator: All Technical Service Bulletins Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 13675 For vehicles repaired under warranty, use the table. Disclaimer Page 1874 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 14706 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 3321 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 18130 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 5017 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Capacity Specifications Coolant: Capacity Specifications Engine Cooling System ....................................................................................................................... .............................................. 17.2 quarts (16.3 liters) Drive Motor Generator Control Module Cooling System ..................................................................................................................... 2.5 quarts (2.4 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 18101 Page 10030 Page 13540 Fuse Block - Auxiliary X3 (HP2) Page 8308 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 12237 Junction Block - Left I/P X10 (except MEX) Page 7294 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7192 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12617 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) Page 9928 23 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 24 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 25 - Transfer Case Oil Pump Assembly 26 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 27 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 28 - Transfer Case Rear Output Shaft Rear Bearing Assembly 29 Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 30 - Transfer Case Oil Pump Suction Pipe Seal 31 - Transfer Case Oil Pump Suction Pipe 32 - Transfer Case Front Output Shaft Rear Bearing Assembly 33 - Transfer Case Front Output Shaft Driven Sprocket Spacer 34 Transfer Case Front Output Shaft Driven Sprocket 35 - Transfer Case Front Output Shaft Hole Plug 36 - Transfer Case Front Output Shaft 37 - Transfer Case Front Output Shaft Front Bearing Assembly Clutch Components Page 18772 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 1412 8. Remove the oil level sensor from the oil pan. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the oil level sensor to the oil pan. Tighten the sensor to 20 Nm (15 lb ft). 2. Connect the engine harness electrical connector (1) to the oil level sensor. Page 11497 Wheel Speed Sensor (WSS) - Right Rear (JL4/HP2) Page 10281 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 11269 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Install the park brake cable assembly into the backing plate. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair) . 3. Install the park brake cable to the cable guides. Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Rear of Tank) Removal Procedure Note Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Lift and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2). 3. Disconnect the vent solenoid hose retainers (1). Page 6737 16. Remove the engine wiring harness clip bolt (4). 17. Gather the branches of the engine wiring harness and reposition the aside. 18. Remove the positive crankcase ventilation (PCV) hose. Page 6579 Fuel: Testing and Inspection Fuel Composition Diagnosis Fuel Composition Diagnosis System Description When an E85 compatible vehicle is built, an engine control module (ECM) or powertrain control module (PCM) replaced, or when the learned alcohol content has been reset with a scan tool, the fuel system will need to contain ASTM gasoline with 10 percent or less ethanol content. If the fuel in the fuel system needs to be drained and replaced with ASTM gasoline, the engine will need to run at operating temperature and consume at least 1 liter (0.3 gallon) of fuel before the system will recognize the correct alcohol content. Either ASTM gasoline or ASTM E85 fuel can then be used. Page 17943 Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Page 13219 Junction Block - Left I/P X1 (except MEX) Page 4165 Fan Shroud: Service and Repair Engine Coolant Fan Upper Shroud Replacement Engine Coolant Fan Upper Shroud Replacement (Mechanical) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor (2). 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. 6. Remove the fan shroud retainers. Page 11691 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10457 Actuator: Diagrams Component Connector End Views Front Drive Axle Actuator (NQF/NQG/NQH) Page 7793 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2941 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 3. Remove the connector position assurance (CPA) retainer (4). 4. Disconnect the engine wiring harness electrical connector (7) from the HO2S. 5. Remove the HO2S electrical connector clip (6) from the fuel line clip. Page 13496 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 7873 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 19606 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 6048 Engine Control Module (ECM) X2 (5.3L/L76 or 6.2L Except Y91) Page 2908 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 10243 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 5153 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). 3. If equipped with 4WD perform the following steps, if equipped with 2WD proceed to step 6. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Install the CPA retainer (2). 6. Connect the HO2S electrical connector (3) to the engine wiring harness electrical connector (5). 7. Install the CPA retainer (2). 8. Lower the vehicle. Page 13919 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5700 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 4642 4. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 5. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 6. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. Page 9411 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution) . Note Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 6. Holding the J 8614-01 - holder , tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. Page 8727 Input Speed Sensor (ISS) (M30) Page 17163 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Page 12216 Page 9065 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 14519 DO NOT re-use the shock absorber nut, discard and replace with new ONLY. 5. Using the appropriate tool, remove and discard the shock absorber nut (1) . 6. Remove the front lower shock absorber (2) and the front spring lower insulator (1). 7. Remove the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) from the spring compressor. Installation Procedure Page 7236 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 1311 1. Install the brake booster vacuum sensor grommet to the brake booster. 2. Install the brake booster vacuum sensor to the brake booster. 3. Connect the chassis wiring harness electrical connector (1) to the brake booster vacuum sensor. Page 5078 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 4507 6. Remove the 3 phase cable retainer nut (2). 7. Remove the 3 phase cable retainer (1) from the bracket. 8. Remove and lower the transmission enough to gain access to the 3 phase cable bracket bolts (1). Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . 9. Remove the 3 phase cable bracket bolts (1). 10. Remove the 3 phase cover bolts (9) and transmission cover terminal housing (8). 11. Remove the 3 phase cover (7). 12. Disconnect the 3 phase cable cover connector. 13. Remove the 3 phase cable bolt protective cover (5). 14. Remove the 3 phase cable retaining bolts (4). 15. Remove the 3 phase cables and housing (3). 16. Finish removal of the transmission while allowing the 3 phase cables to remain in the vehicle. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . 17. Remove the 3 phase cables from the vehicle. Installation Procedure Page 10581 Disclaimer Page 4556 13. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 14. Clean the sealing surface of the PIM cover as necessary. 15. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 16. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . 17. Install the ground strap (2) and bolt (1). Tighten the bolt to 22 Nm (16 lb ft) . Page 7986 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 10133 24 - Transfer Case Oil Fill Plug 25 - Transfer Case Oil Drain Plug 26 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 27 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 28 - Transfer Case Shift Detent Plunger Plug 29 - Transfer Case Shift Detent Plunger Plug - O-Ring - Seal 30 - Transfer Case Shift Detent Spring 31 - Transfer Case Shift Detent Plunger Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 - Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Insert 12 - Transfer Case Shift Fork Spring Page 2170 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Passenger Door Components (except AN3/DL3) Page 16811 Vehicle Communication Interface Module (VCIM) X3 (UE1 with U3U/UVB) Page 10910 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 2458 For vehicles repaired under warranty, use the table. Disclaimer Front Air Deflector Extension Replacement Air Dam: Service and Repair Front Air Deflector Extension Replacement Front Air Deflector Extension Replacement Page 2893 Page 12392 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 17473 For vehicles repaired under warranty, use the table above. Disclaimer Page 2261 Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 5000 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . Page 4418 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 10254 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 9110 Page 17868 Page 2188 Window Switch - Driver X2 (A31 without AN3/DL3) Page 18677 Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Page 14431 9. Remove the 2 pivot pins (3) from the steering column tilt head assembly (1) by using removerJ 21854-01 (2) . 10. Install the tilt lever into the steering column tilt head assembly (1). 11. Pull back on the tilt lever and at the same time, pull the steering column tilt head assembly (1) down and away from the steering column. 12. Remove the steering column tilt head assembly. 13. Remove anti-rotation pinJ 42640 . 14. Remove the tilt lever. 15. Remove the steering shaft upper bearing from the steering column tilt head assembly. Page 2143 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 10294 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 16312 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Page 13763 Page 346 For vehicles repaired under warranty, use the table. Disclaimer Page 13140 Fuse: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 12207 Page 15796 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 7886 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 7402 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Selector Switch - O-Ring - Seal 7 - Transfer Case Shift Control Switch Assembly 8 - Transfer Case Front Half 9 - Transfer Case Half Locating Pin 9 - Transfer Case Half Locating Pin 10 - Transfer Case Input Shaft Bearing Assembly 11 - Transfer Case Input Shaft Inner Retaining Ring 12 - Transfer Case High/Low Internal Gear 13 - Transfer Case High/Low Internal Gear Retaining Ring 14 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 15 - Vehicle Speed Sensor Assembly 16 - Vehicle Speed Sensor O-Ring - Seal 17 - Transfer Case Rear Half 18 - Transfer Case Access Hole Plug 19 - Transfer Case - Harness - Bracket 20 - Transfer Case Half Bolt/Screw (Qty: 17) 21 - Transfer Case Rear Output Shaft Bushing 22 - Transfer Case Rear Output Shaft Seal 23 - Transfer Case Oil Fill Plug 24 - Transfer Case Oil Drain Plug 25 - Transfer Case Front Output Shaft Rear Bearing Assembly 26 - Transfer Case Shift Detent Plunger Plug 27 - Transfer Case Shift Detent Plunger Plug O-Ring - Seal 28 - Transfer Case Shift Detent Spring 29 - Transfer Case Shift Detent Plunger 30 Transfer Case Shift Detent Lever Bearing Assembly 31 - Transfer Case Shift Lever Seal 32 Transfer Case Shift Lever 33 - Transfer Case Control Lever Bolt/Screw 34 - Transfer Case Shift Lever - Rubber - Seal Internal Components Page 6167 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 12042 Fuse Block - Underhood X5 Page 17838 Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Page 4016 1. Compress the timing chain tensioner guide and install the EN 46330 . Note * Properly locate the CMP actuator on the locating pin of the camshaft. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. * DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly. 2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Page 2324 Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 2986 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 5168 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 13505 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12106 Junction Block - Left I/P X2 (except MEX) Page 13161 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 3352 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 13529 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 5650 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 7069 Page 7122 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 1499 Locations Fuel Pressure Sensor/Switch: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 15980 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Front of Vehicle/Engine Compartment Component Views Front of the Vehicle Components (except 10 Series) Page 9503 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Page 2702 Center Instrument Panel Fuse Block CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 Page 5668 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16745 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 3387 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Page 16171 Cellular Phone Microphone: Diagrams Component Connector End Views Cellular Telephone Microphone (UE1/U3U/UVB) Noise Compensation Microphone (UQA with Y91) Page 1832 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector (1). 4. Remove the HO2S clip from the engine wiring harness clip (4). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 5. Remove the HO2S (2). Page 8048 Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 1438 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Page 5481 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 20435 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 10232 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 2072 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 20482 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 11469 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 4018 4. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Page 11863 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Sunshade Anchor Replacement Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 13264 Page 20869 Disclaimer Service Procedure Service Procedure Technicians are to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. If a customer refuses to have this safety recall performed on their vehicle, dealers are to provide the customer with a copy of the "Notice to Customer" document provided in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. A labor code is provided for customers who refuse the repair. This labor code will not close the recall. If the customer, or a new owner, decides at a later date to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. This service procedure will permanently disable and remove the heated windshield washer fluid system. After performing the procedure, dealers are to issue a $100 USD/$105 CDN check to the customer of record as compensation for the loss of this feature (see Q&A; section of this bulletin for additional details). Involved vehicles currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Fuse Removal FUSE REMOVAL 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, 2007-2009 Chevrolet Avalanche, Silverado (GMT900), Suburban, Tahoe, 2007-2009 GMC Sierra (GMT900), Yukon and Yukon XL 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block is located in the engine compartment on the driver side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Page 12745 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (Except MEX) Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 13579 Page 6967 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Page 12018 Fuse Block - Auxiliary X2 (HP2) Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 2804 Fuse Block - Underhood Bottom View Page 8592 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 12490 Page 8109 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. A/T - Production Changes Valve Body: All Technical Service Bulletins A/T - Production Changes INFORMATION Bulletin No.: 08-07-30-041 Date: September 04, 2008 Subject: Information On 2009 M30 4L60E, M32 4L65E and M70 4L70E HYDRA-MATIC(R) RWD Four Speed Automatic Transmission Controls Product Update Models: 2009 Chevrolet Avalanche, Colorado, Express, Silverado, Tahoe, TrailBlazer, TrailBlazer SS 2009 GMC Canyon, Envoy, Envoy Denali, Savana, Sierra, Yukon 2009 Saab 9-7X Models Equipped with HYDRA-MATIC(R) 4L60E, 4L65E, 4L70E Four Speed RWD Automatic Transmission (RPOs M30, M32, M70) For the 2009 model year, there are several controls changes to the 4L60E, 4L65E and 4L70E. The valve body casting has been changed and will not back service due to the removal of the components shown above. Page 9615 1. Install the flywheel and bolts (1) to the crankshaft. 2. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the flywheel bolts. 1. Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft). 2. Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft). 3. Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft). 4. Install the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . Page 8162 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 2372 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 4720 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 2579 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter . 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed Procedure (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed Procedure (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Page 11299 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 3924 29. Unsecure the brake booster vacuum hose from the intake manifold. 30. Install the brake booster vacuum hose to the booster fitting. 31. Position the brake booster vacuum hose clamp at the booster. 32. Untie the engine harness branches from the cowl panel and position over the engine. 33. Connect the engine harness electrical connector (2) to the ECT sensor. 34. Position the engine harness clip (1) to the generator bracket and install the bolt (3). Tighten the bolt to 9 Nm (80 lb in) . Page 14644 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 11729 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 9378 2. Install the following components into the inner axle shaft housing: 1. Install the inner axle shaft (1) into the inner axle shaft housing (4). 2. Install the thrust washer (with tabs) (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. 3. Install the thrust washer (without tabs) (6). 4. Install the retaining ring (7) into the inner axle shaft (1). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Note In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring. 4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go. 5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 10953 Page 15098 HVAC Control Module X3 (C67/C42/CJ2/MEX) Page 20815 Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Locations Vehicle Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 19636 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 12945 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7))Front Brake Rotor Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) . 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7))Front Brake Rotor Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) . 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 4. Lower the vehicle. Page 6670 32. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for leaks. 33. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Auxiliary Battery Positive Cable Replacement Positive: Service and Repair Auxiliary Battery Positive Cable Replacement Auxiliary Battery Positive Cable Replacement Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . 2. Remove the underhood junction block cover. 3. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 4. Remove the junction block. Page 7588 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 11614 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (With V8 Engine) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 17931 Sun Visor: Service and Repair Sunshade Replacement Sunshade Replacement Page 13903 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Page 2812 Fuse Block - Underhood X4 Page 13567 Page 484 Page 5820 and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, setup, and programming Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool B+ voltage at terminal 16 * Scan tool ground at terminal 4 * Common ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Testing Page 9192 Page 2693 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 13831 Page 5942 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 9382 Note Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement) . 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . 2. Place the differential carrier assembly into a vise. Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as Page 19651 Compass: Locations Passenger Compartment/Roof Component Views Top of the Headliner Components (Regular Cab) 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 3666 Page 18334 5. Slide the water gutter rearward to release the retaining tabs (1) from the slots (2) in the track. 6. Remove the water gutter (3) from the track. Installation Procedure 1. Position the sunroof water gutter to the sunroof window track. 2. Seat the retaining tabs (1) on the water gutter (3) into the slots (2) in the track, and push the water gutter forward until the retaining tabs lock into place. 3. Ensure that all 6 tabs are secured. Page 19491 Cruise Control: Testing and Inspection Cruise Control Malfunction Cruise Control Malfunction Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The body control module (BCM) supplies battery voltage to the cruise control switch. The cruise control switch signal is an input to the BCM. The BCM monitors the cruise control switch signal circuit in order to detect when the driver has requested to perform a cruise control function. The BCM detects a specific voltage signal on the cruise control switch signal circuit when a switch is applied. Reference Information Schematic Reference * Cruise Control Schematics (See: Diagrams/Electrical Diagrams) * Steering Wheel Secondary/Configurable Control Schematics (See: Accessories and Optional Equipment/Diagrams/Electrical Diagrams/Steering Wheel Secondary/Configurable Control Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Cruise Control Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Engine ON, while rotating the steering wheel to both steering stops, observe the scan tool Cruise Control Switch parameter while pressing each of the cruise control switches. The parameter should toggle between On, Off, Resume, Set, and Cancel as the applicable switch is pressed. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition ON, test for B+ between the B+ circuit terminal 1 and ground. Page 15443 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Inflator Module Deployment - Component Inspections Warning Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. * The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection (See: Steering Column) . * The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks (See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Operational and Functional Checks) . * The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Note The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to disable/turn off the I/P air bag, even in a accident. For more information on the PPS refer toSIR System Description and Operation (See: Air Bag Systems/Description and Operation) . * Inflatable restraint front end sensors * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint sensing and diagnostic module (SDM) * Inflatable restraint steering wheel module * Inflatable restraint steering wheel module coil * Seat belt pretensioners Perform additional inspections on the following components: * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. * Passenger Presence System (PPS) for damage to the wiring or pressure system Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components: * Inflatable restraint roof rail module, on the side of the impact. * Inflatable restraint side impact sensors (SIS) (front/rear), on the side of the impact * Inflatable restraint SDM * Seat belt pretensioner, on the side of impact. Perform additional inspections on the following components: Page 7883 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10367 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 17012 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3120 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 5230 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 20068 Hazard Flasher Relay: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 11574 Negative: Service and Repair Battery Negative Cable Replacement Battery Negative Cable Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions) . 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (1) from the battery current sensor (2). 3. Remove the negative battery cable clip (1) from the auxiliary bussed electrical center (BEC). Page 9608 8. Position the universal spider (2) in the slip yoke (1). 9. Install the universal bearings (2) in either side of the slip yoke (2). 10. Fully seat one of the universal spiders in the universal bearing. 11. Press the universal bearings (2) into the slip yoke (2) until it is even with the yoke. 12. Install the retaining ring (1) in the slip yoke (3). 13. Rotate the slip yoke and repeat steps 3-5 for the opposite universal bearing. Page 8110 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 15277 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 5846 Page 4251 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 5946 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 3847 Installation Procedure Note * The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. * Do not reuse the oil pan gasket. * It is not necessary to rivet the NEW gasket to the oil pan. 1. If reusing the oil pan perform the following step, otherwise proceed to step 3. Note Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 2. Place a NEW oil pan gasket onto the oil pan. 3. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . 4. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Page 17553 Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Extender Cab) Rear Side Door Window Replacement (Extender Cab) Page 8266 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 11742 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 652 Body Control Module (BCM) X7 (Except MEX/A52) Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 19451 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 3863 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Intake Manifold/Service and Repair) . Page 7155 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12740 Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 15019 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 5051 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 3879 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 596 Page 2843 Junction Block - Left I/P X10 (except MEX) Page 7165 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 15234 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 7824 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9012 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 1959 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Driver Door Components (AN3/DL3) Page 10365 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 18451 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 1463 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 15347 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 6372 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10651 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 10383 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 12244 Page 16805 Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 15462 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 4453 Drive Motor Generator Battery Control Module X5 (HP2) Page 20260 Page 8222 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 14226 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install a new pitman arm washer (2) and nut (1). Tighten the nut to 250 Nm (184 lb ft). 3. Remove the steering gear from the vise. 4. Install the steering gear. Refer to Steering Gear Replacement (Two Mode Hybrid) (See: Steering Gear/Service and Repair)Steering Gear Replacement (Non-Rack and Pinion) (See: Steering Gear/Service and Repair)Steering Gear Replacement (Rack and Pinion) (See: Steering Gear/Service and Repair) . 5. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Page 6768 17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 20. Install the fuel line clip to the bracket on the automatic transmission. Page 19547 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 10170 Harness Components Page 18444 For vehicles repaired under warranty, use the table. Disclaimer Page 13563 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 11641 Page 7966 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 1195 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Page 6148 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 6208 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 5658 Module Circuit Function Icons Page 16607 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 1646 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Rear Side Access Door Trim Panel Replacement Rear Door Panel: Service and Repair Rear Side Access Door Trim Panel Replacement Rear Side Access Door Trim Panel Replacement Page 10332 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 6483 See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Evaporative Emission Line Replacement - Chassis (Extended/Crew Cab) Evaporative Emission Hose/Pipe Replacement - Chassis (1500 Extended/Crew Cab) Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Unbolt and reposition the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement () . Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 11929 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 20106 Headlamp Bulb: Service and Repair Headlamp Bulb Replacement (Chevrolet) Page 18651 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1316 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 2916 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 19489 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition ON, verify that a test lamp illuminates between the signal circuit terminal 9 and B+. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 3. If all circuits test normal, test or replace the steering wheel controls switch - left. Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup, and programming Page 9482 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 12713 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 10135 Transfer Case Actuator: Locations Powertrain Component Views Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement (Chevrolet) Page 15839 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 4280 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Tighten the bolts to 9 Nm (80 lb in). 2. Clean the threads of the exhaust manifold bolts. 3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. 4. Install a NEW catalytic converter seal to the catalytic converter. 5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head. 6. Ensure that the exhaust manifold is seated to the catalytic converter. 7. Install the exhaust manifold bolts. 1. Tighten the bolts a first pass to 15 Nm (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 2. Tighten the bolts a final pass to 20 Nm (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Page 8789 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9484 Note Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Page 16255 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 3340 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 5702 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8015 Transfer Case Actuator: Locations MP 3023/3024-NQH - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 18546 Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Page 5409 Body Control Module (BCM) X4 Page 6284 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector (1). 4. Remove the HO2S clip from the engine wiring harness clip (4). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 5. Remove the HO2S (2). Page 12124 Junction Block - Right I/P X3 Page 19612 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 3985 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 10. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Page 18214 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 5896 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 7. Remove the HO2S (4). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 9580 12. Remove the propeller shaft from the transmission or the transfer case. Installation Procedure Note If servicing a propeller shaft with a slip yoke, proceed to step 1. If servicing a propeller shaft with the yoke attached to the output shaft of the transmission or the transfer case, proceed to step 3. 1. Align the reference marks on the transmission or the transfer case (1), slip yoke (2), universal bearing cap (3), and the propeller shaft. 2. Install the propeller shaft. Page 3085 Fuse Block - Underhood X5 Page 3918 1. If the intake manifold was replaced perform the following steps, otherwise proceed to step 21. Note Evenly push in the RED collar in order to install the nipple. 2. Install the brake booster vacuum hose nipple to the NEW intake manifold. 3. Install NEW fuel injector lower O-ring seals onto the injectors. 4. Lubricate the NEW O-ring seals with clean engine oil. Note Push down firmly on both sides of the rail until all the injectors have been seated into their bores. 5. Install the fuel rail. Page 7754 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 20445 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 3976 Timing Chain: Service and Repair Timing Chain, Crankshaft Sprocket, Camshaft Position Actuator and Solenoid Valve Replacement Timing Chain, Crankshaft Sprocket, Camshaft Position Actuator and Solenoid Valve Replacement Special Tools * EN 46330 Timing Chain Tensioner Retaining Pin * J 8433 Puller Bar * J 41478 Crankshaft Front Oil Seal Installer * J 41558 Crankshaft Sprocket Remover * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 2. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Page 18735 Switches and Relays Page 13141 Page 1520 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 16168 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Instrument Panel/Center Console Component Views Console Components Page 15547 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series Except ASF/MEX/Crew Cab) Page 2409 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 13634 Page 12039 Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Page 5844 Page 13427 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 18785 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 20481 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 610 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 14270 connector until it is fully disengaged. 5. Push the connector cam lever (3) toward the rear of vehicle. Note Note the routing and any mounting points for the power steering assist motor electrical harness. Also note any other electrical harnesses that will need to be re-secured to it after installation. Use new retainers and tie straps as needed. 6. Separate the power steering assist motor electrical harness retainers from the electronic power steering control module bracket and disengage the electrical connectors (1). 7. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 8. Remove the steering linkage shield bolts (1) and the steering linkage shield (2). 9. Separate the power steering assist motor electrical harness retainers from the frame of the vehicle. 10. Pull the power steering assist motor electrical harness through the engine compartment to the bottom of the vehicle. Page 440 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9548 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5903 4. Install the CPA retainer (5). 5. Lower the vehicle. Page 6984 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 19735 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 9776 Disclaimer Page 12092 Fuse Block - I/P X2 (except MEX) Page 3393 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 13327 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 7760 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 8446 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 13291 Fuse Block - Auxiliary X2 (HP2) Page 13444 View of the connector when released from the component. View of another type of Micro 64 connector. Page 10382 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 16551 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5053 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 7126 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17190 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 14889 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12204 Fuse Block - Underhood X3 Page 5503 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 18811 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 7494 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 17187 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 8764 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 7920 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9501 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Page 4857 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 8334 For vehicles repaired under warranty, use the table. Disclaimer Page 13768 Page 10299 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 11871 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 13734 X129 Inline Harness Connector End Views X129 I/P Harness to Chassis Harness (HP2) Page 12492 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 7922 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 18670 Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Page 13420 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9021 View of the connector when released from the component. View of another type of Micro 64 connector. Page 20115 Page 15975 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Driver Door Components (AN3/DL3) Page 3778 Installation Procedure Important: Discard the EOC retaining clip and install a new retaining clip. 1. Install the EOC pipe into the EOC pipe fitting. A distinct snap should be heard or felt when assembling the EOC pipe to the fitting. 2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull. Page 12425 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 17446 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Page 6067 Page 655 Page 5434 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Diagram Information and Instructions Charging System: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 6470 2. Connect the EVAP line quick connect fittings at the fuel tank module and vent valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Install the EVAP lines to the fuel tank clips (1, 3, 4, and 5) and close the clips. 4. Install the EVAP lines to the fuel tank clips (2, and 6). 5. Install the fuel tank shields (1, and 4) and retainers (2, and 3). 6. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 19538 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5452 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 5703 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 10048 Disclaimer Page 13862 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 12992 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2959 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 15554 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab Except 10 Series) Locations Vehicle Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set PROM - Programmable Read Only Memory: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 1434 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 20912 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 5327 5. Install the spark plug wire to the spark plug. 6. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 7. If a right side spark plug(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 8. If a right side spark plug(s) was replaced, perform the service reconnect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 4027 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 17883 Disclaimer Page 11362 Trailer Brake Control Module (JL1 with 31 Series) Page 13483 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: Customer Interest Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5425 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 11946 Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Page 8935 6. Install the range selector lever cable heat shield (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. 9. Install the clips on the cable to the floor panel reinforcement. 10. Lower the vehicle and ensure that the steering column shift lever is still in the park position. 11. Install the cable grommet to the floor panel. Page 12128 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 15578 Note Do not remove the centering tab from the new inflatable restraint steering wheel module coil until the installation is complete. If the centering tab is missing then re-center the assembly. 1. If reusing the existing inflatable restraint steering wheel module coil it MUST be centered. Refer to Inflatable Restraint Steering Wheel Module Coil Centering (See: Procedures) . 2. Align the inflatable restraint steering wheel module coil (1) with the horn tower on the turn signal switch cancel cam (2). 3. Slide the inflatable restraint steering wheel module coil (4) onto the steering shaft (2). 4. Firmly seat the new inflatable restraint steering wheel module coil retaining ring (3) into the appropriate groove on the steering shaft (2). 5. Remove and discard the centering tab from the new inflatable restraint steering wheel module coil (4). 6. Connect any electrical connectors as needed. 7. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 8. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement) . 9. Remove anti-rotation pinJ 42640 . Page 13818 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 13601 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 2802 Page 7266 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 13971 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 1945 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 18973 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 384 Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 2742 Page 15264 Page 11015 Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 19027 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 11627 ^ Increased internal generator temperatures from extended idling can also contribute to lower electrical system voltage. As the generator's internal temperature rises, the generator's output capability is reduced due to increased electrical resistance. Some typical examples of electrical loads are shown above. Depending on the vehicle application, generator current (amperage) output at engine idle speeds of 600-700 RPM can be as low as 35 percent of the full rated output. With enough electrical loads "ON", it is easy to exceed the generator current (amperage) output when the engine is at an idle of 600-700 RPM. This is a normal condition. The battery supplements for short periods of time. Items that affect the vehicle's electrical system current and voltage at idle are the number of electrical loads being used, including add-on accessories, and extended idle times. When the vehicle speed is above approximately 24 km/h (15 mph), the engine/generator RPM is high enough and the generator current (amperage) output is sufficient to supply the current (amperage) requirements of the vehicle as originally equipped and recharge the battery. Dimming lights at idle may be considered normal for two reasons: 1. As the engine/generator speed changes, so will the current (amperage) output of the generator. As a vehicle slows, engine/generator RPM slows and the current (amperage) output of the generator may not be sufficient to supply the loads, the vehicle system voltage will drop and the lights will dim. Dimming of the lights is an indication that current is being pulled from the battery. If the battery is in a low state-of-charge (discharged condition), the driver will notice a more pronounced dimming than a vehicle with a fully charged battery. 2. When high current loads (blower, rear defogger, headlamps, cooling fan, heated seats, power seats, electric "AIR" pump, or power windows) are operating or cycled "ON", the generator's voltage regulator can delay the rise in output. This effect, usually at lower engine speeds, can take up to ten seconds to ramp up the generator output. This is done to avoid loading the engine severely. To increase current (amperage) output, additional torque is consumed by the generator. The engine computer (ECM/PCM) will ramp up engine/generator speed in small steps so engine speed variations are not noticeable to the driver. For diagnosis of the battery and/or the generator, refer to the appropriate Service Information (SI) or Corporate Bulletin Number 05-06-03-002C. Disclaimer Page 18059 Door Lock/Window Switch - Driver X4 (AN3) Page 18749 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 12228 Page 6983 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 4530 * Accessory DC power control module (APM) * Battery energy control module (BECM) * Motor control module (MCM) 1 * Motor control module (MCM) 2 * Auxiliary transmission fluid pump (ATFP) control module These modules diagnose their own operation and determine when a fault condition is present. Diagnostic status is communicated to the HPCM through the following circuits: * APM utilizes the GM Hi-speed, Hybrid LAN communication circuit * BECM utilizes the GM Hi-speed, Hybrid LAN communication circuit * Each MCM and the HPCM exchange information and commands on the SPI bus internal communication circuit as well as the hi-speed hybrid GMLAN communication circuit. * ATFP control module utilizes a dedicated diagnostic status circuit In the event a hosted module communicates a fault condition, the HPCM will determine if hybrid operation is effected and notify the vehicle operator by requesting the MIL illuminate and/or by displaying a hybrid service required message. In addition, the HPCM will store the associated DTC information for retrieval by a scan tool. Some hosted modules may require an ignition cycle to clear certain DTCs from the HPCM. Circuit Inputs In addition to GMLAN parameters, the HPCM directly monitors the following signal circuits: * Transmission shift selector internal mode switch (IMS) Direction and Park/Neutral switch signals * Engine crankshaft position (CKP) sensor signal * ATFP diagnostic circuit * High voltage interlock circuit (HVIC) Circuit Outputs In addition to GMLAN and SPI bus commands, the HPCM directly controls the following output circuits: * ATFP control circuit * BECM high voltage contactor relay pulse width modulated (PWM) control circuit Motor Control Module (MCM) 1 and 2 Location Each electric motor generator located within the transmission assembly is controlled by its own motor control module (MCM) flash-programmable, micro-processor. Each MCM is contained within the PIM. Also contained within the PIM is the hybrid powertrain control module (HPCM) micro-processor. Operating Functions Each MCM operates the applicable electric motor generator based upon HPCM commands. Each MCM controls the speed, direction and output torque of its respective traction motor through the sequencing actuation of high current switching transistors called insulated gate bipolar transistors (IGBTs). Communication and Hosted Diagnostics In addition to the internal SPI bus communication circuit between the HPCM and each MCM, the MCMs also communicate on the Hi-speed and Hybrid GMLAN communication circuits. The MCM does not store its own diagnostic trouble code (DTC) information. The HPCM will store MCM associated DTC information for retrieval by a scan tool. The scan tool can communicate directly with each MCM in order to retrieve data parameters only. Circuit Inputs In addition to GMLAN parameters, each MCM monitors its respective motor generator for voltage, current, speed, direction and temperature. Additionally, the MCM monitors the IGBT components for temperature and proper operation. Some of the MCM operation data is shared with the HPCM. Circuit Outputs Each MCM controls its respective IGBT driver board that in-turn controls each motor generator. The motor generators operate using three-phase alternating current (AC) electricity. Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician that the potential for high voltage is present. Page 12268 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Rear License Plate Lamp Replacement (Silverado) License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement (Silverado) Rear License Plate Lamp Replacement (Silverado) Removal Procedure 1. Ensure the headlamp switch is in the OFF position. 2. Reach under the rear bumper and press on the lens end of the cover in order to release the locking tab. 3. Remove the lens housing from the bumper assembly. 4. Remove the bulb. Installation Procedure 1. Install the bulb. 2. Install the rear edge of the lens housing into the rear bumper. 3. Push on the lens side of the housing in order to snap the housing into the rear bumper assembly. 4. Inspect the operation. Page 7921 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9583 9. Apply a small amount of clean chassis grease to the slip yoke and the rear propeller shaft. 10. Install the rear portion of the propeller into the front portion of the propeller shaft. 11. Align the reference marks on the rear axle housing (6), pinion yoke (5), universal bearing cap (4), and the rear propeller shaft (1). 12. Install the straps (2) and the bolts (3). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 13. Using the J 43218 , crimp the boot clamps until the dimensions shown are obtained. 14. Remove the support and lower that vehicle. Page 11034 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) . Page 16788 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 15056 Page 19951 Page 19997 Courtesy Lamp: Service and Repair Pickup Box Identification Lamp Replacement (Chevrolet HD) Pickup Box Identification Lamp Replacement (Chevrolet HD) Page 11202 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 15876 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 12060 Page 15301 Page 11749 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Locations Keyless Entry Receiver: Locations Passenger Compartment/Roof Component Views Rear of the Passenger Compartment Components 1 - Information Center Telltale Assembly (UD7) 2 - Sliding Rear Window Open Relay (A48) 3 Sliding Rear Window Close Relay (A48) 4 - Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) 5 - Sliding Rear Window Motor (A48) Page 7870 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 15526 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 13159 Page 17231 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 5604 Engine Control Module (ECM) X2 (5.3L/L76 or 6.2L Except Y91) Testing and Inspection Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires, Incorrect routing may cause cross firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for any of the following conditions: * Tearing * Piercing * Arcing * Carbon tracking * Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal, replace the wire and the component connected to the wire. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to theMaster Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 13330 Fuse Block - Auxiliary (HP2), Bottom View Page 5615 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 10631 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Page 3495 1. Lubricate the valve lifters (209) and engine block valve lifter bores with clean engine oil. 2. Insert the valve lifters into the lifter guides (210). Align the flat area on the top of the lifter with the flat area in the lifter guide bore. Push the lifter completely into the guide bore. 3. Install the valve lifters and guide (210) to the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the valve lifter guide bolts. Tighten the bolt to 12 Nm (106 lb in). 5. Install the cylinder head and gasket. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair) . Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 13625 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 10442 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 6044 Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 9570 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20546 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 6017 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 4595 Drive Motor Generator Battery Control Module X2 (HP2) Page 6686 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 2522 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Page 4433 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 6879 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 11147 1. Install the master cylinder adapter gasket, if removed. 2. Install the brake master cylinder adapter (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the 4 brake pedal bracket nuts (1) and tighten to 25 Nm (18 lb ft) . Service and Repair Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement Removal Procedure Note Transfer all necessary parts to the new sunroof module assembly. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair )Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 2. Remove the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)) . 3. Remove the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)) . 4. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair )Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair) . 5. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 6. Disconnect the front sunroof drain hoses from the drain spigot. 7. Disconnect the rear sunroof drain hoses from the drain spigot. Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Page 15418 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Low Pressure Sensor (HP2) A/C Low Pressure Switch Page 13643 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 5769 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 2645 Page 12292 Door Lock Cylinder Replacement Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Door Lock Cylinder Replacement Page 12592 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Page 1748 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 13672 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Specifications Spark Plug: Specifications Ignition System Specifications Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 7334 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 19785 Page 15324 Page 5368 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 11608 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 11720 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 12388 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 5603 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 9594 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10395 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8242 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 13406 Page 7564 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 14892 Air Door Actuator / Motor: Diagrams Component Connector End Views Recirculation Actuator (C67/CJ2) Mode Actuator (C67/C42/CJ2) Page 4934 Page 15484 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2799 Page 6940 Note Verify that the engine wiring harness electrical connector seal for the electronic throttle control is properly installed and not damaged. 3. Connect the engine wiring harness electrical connector (2) to the electronic throttle control. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 8. Start the engine. 9. Inspect for coolant leaks. 10. Perform the throttle learn procedure. Refer to Throttle Learn (See: Procedures/Throttle Learn) . Page 858 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab Except 10 Series) Page 7014 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 20188 Page 12717 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Headliner Harness (UE1/U3U/UVB) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 8159 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15844 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 19151 11. Reinstall the foam (1) to the latch rod. 12. Reinstall the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 13. Reinstall the right endgate latch. Refer to Endgate Latch Replacement in SI. 14. Reinstall the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6053 Engine Control Module (ECM) X2 (HP2) Page 10553 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Rear Side Door Inside Handle Replacement (with SLT) Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (with SLT) Rear Side Door Inside Handle Replacement (with SLT) Page 19666 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 13202 Fuse Block - Underhood X6 Page 18009 Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 3373 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 6985 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 5134 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems) . 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages () . Page 5699 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 8108 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19949 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Fluid Pump: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 15798 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 10074 Seals and Gaskets: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Page 5159 4. Install the CPA retainer (5). 5. Lower the vehicle. Page 16480 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 4979 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 212 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 15957 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the seat belt pretensioner connector. 17. Route the deployment harness out of the driver side of the vehicle. 18. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Page 7501 Transmission Control Module (TCM) (MW7) Page 2978 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 8416 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 4613 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Page 2402 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Page 9606 11. Remove the retaining ring (1) from the slip yoke (3). 12. Using the J-9522-3 - Separator ,J-9522-5 - Remover and a press, remove the universal bearing (2) from the yoke (3). 13. Remove the spider (2) from the slip yoke (1). 14. Thoroughly clean the slip yoke and the propeller shaft yoke of any contaminates that could prevent the retaining rings or the bearing cups from being properly installed. Installation Procedure Note If replacing the propeller shaft slip yoke, proceed to step 8. Page 10414 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10241 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 12288 Component Parts Page 6520 kPa (43 - 45 psi). Circuit/System Testing Important: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from theCH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with theCH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (2500/3500 Regular Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Crew Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement Chassis (1500 Regular Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Extended Cab) (See: Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Service and Repair )Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair) Page 6637 Fuel Injector 3 (4.3L) Fuel Injector 3 (4.8L/5.3L/6.0L/6.2L) Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Sunroof Sunshade Replacement (Extended Cab) Sun Shade: Service and Repair Sunroof Sunshade Replacement (Extended Cab) Sunroof Sunshade Replacement (Extended Cab) Removal Procedure Important: If the sunshade spring releases, it will be necessary to rewind it. Turn the sunshade roller end slot 20 times in the counterclockwise direction. Important: A new sunshade service part comes pre-loaded with a pin tool holding spring tension on the sunshade. If the sunshade spring releases, it will be necessary to rewind it and reinstall the pin tool. Following installation, retain the pin tool for future applications. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair )Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 2. Power the sunroof window guides to the fully open position. Important: The cam locking hole will come in to view when the sunshade is in the fully open position on the passengers side. 3. Close the sunshade (1) until the cam locking hole (2) come in to view. Page 7699 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. 6. Install the range selector lever cable heat shield (2). 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. Page 11563 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions) . 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery Cable/Service and Repair) . 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. Page 11734 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 16074 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 5524 * Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position. * Forced idle mode-The ECM will perform the following actions: - Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. - Ignore the accelerator pedal input. * Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator. Page 3984 Note * Properly locate the CMP actuator onto the locating pin of the camshaft. * The sprocket teeth and timing chain teeth must mesh. * The camshaft and the crankshaft sprocket alignment MUST be aligned properly. * Do not use the CMP solenoid valve again. Install a NEW CMP valve during assembly. 7. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of he camshaft. 8. Align the CMP actuator so the timing mark is in the 6 o'clock position. 9. Install the CMP actuator (235) and timing chain (208). Align the hole in the face of the CMP actuator with the locating pin on the front face of the camshaft. Page 2018 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 3365 Disclaimer Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 15275 Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 3652 11. Carefully release the valve spring tension. 12. Remove the J 38606 . 13. Remove the valve spring cap (224). 14. Remove the valve spring (223). 15. Remove the valve stem oil seal (222). 16. Remove the valve (228). Installation Procedure 1. Clean the cylinder head valve spring seat area. 2. Lubricate the valve guide and valve stem oil seal with clean engine oil. 3. Install the valves (228) into the proper port. 4. Install the valve stem oil seal (222). 5. Install the valve spring (223). 6. Install the valve spring cap (224). 7. Compress the valve spring using the J 38606 . 8. Install the valve keys. * Use grease in order to hold the valve keys in place. * Make sure the keys seat properly in the groove of the valve stem. * Carefully release the valve spring pressure, making sure the valve keys stay in place. * Remove the J 38606 . * Tap the end of the valve stem with a plastic faced hammer to seat the keys, if necessary. Page 14498 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Page 3952 3. Ensure that the oil pan drain plug is tight. Tighten the drain plug to 25 Nm (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities . 6. Start the engine and inspect for leaks. Page 13578 Page 10930 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 13255 Fuse Block - I/P Top View Locations Air Bag Deactivation Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 1878 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 10756 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 17445 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 1546 Fuel Pump and Sender Assembly - Rear (LY6 without NQZ Except MEX) Page 19772 Frequently Asked Questions Disclaimer Page 6246 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 18566 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 3217 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 19018 For vehicles repaired under warranty, use the table. Disclaimer Page 11358 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 9074 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11319 Hydraulic Brake Booster: Service and Repair Power Brake Booster Pump Replacement Power Brake Booster Replacement (Adjustable Pedals) Page 7935 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Clamp: Customer Interest Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Page 17314 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Page 18863 Page 2041 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 12628 Page 5512 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Passenger Compartment/Roof Component Views Left Side of the Passenger Compartment Components (Extended/Crew Cab) Page 15626 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 15614 Seat Occupant Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 16197 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 17266 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Brace Replacement Front Bumper Impact Bar Brace Replacement Page 19433 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 18736 Page 13048 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12199 Fuse Block - Underhood X1 Page 13153 Page 13566 Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 13748 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 18262 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Page 2031 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 11151 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Page 19517 Devices and Sensors Page 9317 Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 8790 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 126 Disclaimer Page 12647 Page 10684 Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Page 10776 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) Page 5040 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 17317 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Page 6207 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 15350 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 7304 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 20743 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Page 10432 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 18488 Power Seat Motor: Diagrams Component Connector End Views Seat Front Vertical Motor - Driver (HP2) Seat Front Vertical Motor - Passenger (HP2) Page 17096 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 6439 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 2854 Page 17816 Carpet: Service and Repair Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) Page 11125 1. Lubricate the master cylinder reservoir seals (1) and the outer surface area of the reservoir-to-housing barrels with GM approved brake fluid from a clean, sealed brake fluid container. 2. If reinstalling the master cylinder reservoir, clean the reservoir with denatured alcohol, or equivalent and allow to dry. 3. Install the master cylinder reservoir seals to the master cylinder. Ensure the master cylinder reservoir seals are fully seated in the master cylinder body. 4. Lubricate the master cylinder reservoir-to-master cylinder barrels with GM approved brake fluid from a clean, sealed brake fluid container. 5. Carefully press the master cylinder reservoir (1) straight downward and install the reservoir to the master cylinder. Page 8311 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 3442 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Page 18778 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10788 6. Select Automated Bleed 11. Press Start to begin the automated bleed procedure. Ensure the J-29532-A orJ 29532 has not yet been installed to the vehicle. The travel and pressure sensors are being calibrated and learned by the EBCM during this step. 12. Press Start to continue. Note Approximately 2.5-3.0 L (2.6-3.2 qt) of brake fluid will be used throughout this procedure. Ensure there is an adequate supply of brake fluid in the J-29532-A orJ 29532 . 13. Inspect the fluid level in the J-29532-A orJ 29532 . Clean the outside of the J-29532-A orJ 29532 and add GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container, as necessary. 14. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Note Do not pressurize the J-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. 15. Install the J 35589-A and the J-29532-A orJ 29532 to the vehicle. Note Ensure a MINIMUM of 200 kPa (30 psi) of pressure is MAINTAINED in the J-29532-A orJ 29532 throughout this procedure, except as instructed. 16. Set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). 17. Open the J-29532-A orJ 29532 fluid tank valve to allow pressurized brake fluid to enter the brake system. 18. Wait approximately 30 seconds, then inspect the entire hydraulic brake system to ensure there are no existing external brake fluid leaks. 19. Secure bleeder hoses to all 4 brake caliper bleeder valves. 20. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 21. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 22. Press Start to begin the system automated bleed steps. Follow all instructions on the scan tool. Only apply the brake pedal when instructed to do so by the scan tool. 23. When instructed, firmly apply and release the brake pedal using smooth, consistent full brake pedal strokes. The brake pedal will go fully to the floor with some pedal feedback felt. The master cylinder reservoir supply circuit is being flushed through these steps. 24. Continue the brake applications until instructed by the scan tool. The scan tool will instruct to perform 10 brake applies. 25. When instructed by the scan tool, stop performing the brake applications and press Enter. The scan tool will instruct to perform Steps 23-25 2 more times. 26. When instructed by the scan tool, press Start to continue. Note The hydraulic brake system will be under high pressure during the next bleed sequence. Ensure the bleeder hose is maintained securely to the bleeder valve, and open the bleeder valve slowly. 27. Following the instructions on the scan tool, open the left rear (LR) brake caliper bleeder valve. 28. With the bleeder valve open and the bleeder hose maintained firmly in place, press Start to begin the bleeding process. This process will run in a 30-second cycle. The pump and HPA circuits are being flushed during these steps. 29. Press Enter when instructed to repeat the bleeding process 5 more times on the scan tool. 30. Press Enter when instructed at the end of the 6th bleeding process. 31. Ensure the LR brake caliper bleeder valve is tightened securely. 32. Reduce the charge in the air tank of the J-29532-A orJ 29532 to 0 kPa (0 psi). 33. Press Start to continue. The brake pedal simulator circuit is being flushed through this step. 34. Place shop cloths beneath the master cylinder brake pipe connections to protect the vehicle from the brake fluid expelled during the next sequence. 35. When instructed by the scan tool, set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). Page 17380 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair ) orRear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 7. Inspect the door closing effort and seal to door fit. Page 15675 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 18801 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 11011 Page 4490 Drive Motor Power Cable: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label Page 15238 Page 10313 Module Circuit Function Icons Page 10822 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Page 721 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 13960 Disclaimer Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 2120 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 19404 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 9769 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Component Locations Power Seat Switch: Component Locations Passenger Seat Components - 1 of 2 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 12928 Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Passenger Compartment/Roof Component Views Driver Seat Components - 2 of 2 Page 7291 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 2851 Page 13655 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 13468 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 2792 Fuse Block - I/P X3 Page 354 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 11271 Adjuster Disabling) . 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 9. Disconnect the park brake cable eye (2) from the park brake actuator lever. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Page 11984 Disclaimer Page 18658 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 6108 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12190 Page 18236 Page 2300 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. If replacing the right side spark plug(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug(s) through the wheel opening. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 2. If replacing the right side spark plug(s), perform the service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 3. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. Page 9896 Page 8046 Module Circuit Function Icons Page 8792 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3764 11. Install the engine oil cooler hose/pipe adapter bolts (2) and: Tighten Tighten the bolts to 12 Nm (106 lb in). 12. Install the engine oil cooler hose/pipe retaining bracket bolt (1) and: Tighten Tighten the bolt to 25 Nm (18 lb ft). 13. Verify the correct engine oil level. 14. Verify the repair. Refer to Oil Leak Diagnosis in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 3119 Page 11307 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Page 16327 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 20253 Page 11795 Page 5587 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 12787 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Page 14473 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (1500) Special Tools * J 43631 - Ball Joint Separator * J 45851 - Ball Joint Separator Protector Adapters Removal Procedure Note For vehicles equipped with the aluminum lower control arm, the ball joint is NOT service separately. If the ball joint in the aluminum lower control arm is found to have excessive wear and is damaged, replace the lower control arm as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Remove the stabilizer shaft link from the lower control arm. Refer to Stabilizer Shaft Link Replacement (2500, 3500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair)Stabilizer Shaft Link Replacement (1500) (See: Stabilizer Bar/Stabilizer Link/Service and Repair) . 4. Remove the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 5. Using mechanics wire or equivalent, support the knuckle assembly and upper control arm. 6. Remove and discard the lower ball joint retaining nut. Page 18740 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 3561 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 17639 Endgate Emblem/Nameplate Replacement (TUF) Endgate Emblem/Nameplate Replacement (TUF) Tire Monitor System - Tire Pressure Light Stays ON Door Module: All Technical Service Bulletins Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Page 8415 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 3277 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4032 * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 . 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Remove the J 37287 andCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal ). 5. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system components test normal, refer toSymptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Locations Battery Bus Module: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 2982 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Diagrams Oil Level Sensor: Diagrams Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Page 13774 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (Except MEX) Page 13591 Fuse Block - Underhood X3 Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10903 WARRANTY INFORMATION Page 20940 Page 11311 1. Install the brake booster vacuum sensor grommet to the brake booster. 2. Install the brake booster vacuum sensor to the brake booster. 3. Connect the chassis wiring harness electrical connector (1) to the brake booster vacuum sensor. Page 16654 Page 18524 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 Entertainment System - DVD Screen Off After Ign. Cycle DVD Player: Technical Service Bulletins Entertainment System - DVD Screen Off After Ign. Cycle INFORMATION Bulletin No.: 06-08-44-035C Date: August 04, 2009 Subject: Rear DVD Screen Off After Ignition Key is Cycled (Nav and Non-Nav Radios) Operating Instructions Models: 2007-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra (Crew Cab Only), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 HUMMER H2, H2 SUT 2007-2009 Saturn OUTLOOK Supercede: This bulletin is being revised to add NAV radios and additional information. Please discard Corporate Bulletin Number 06-08-44-035B (Section 08 - Body & Accessories). Some customers may comment that the rear DVD screen will not turn back ON after an ignition key cycle. This is a normal operating characteristic and no repairs should be made to the DVD screen. Notice Some early build vehicles may operate in a different manner and may turn back on after an ignition key cycle. This operation may change when the vehicle's radio has been replaced or the software has been updated due to a service concern. Also, some customer's may compare their vehicle to an early built vehicle that is not operating to design intent. This bulletin is to advise that this is the design intent of the vehicle and no repair attempts should be performed to change this operation. Advise the customer to either: 1. Press the power (ON/OFF) button on the remote control to turn ON the DVD screen. 2. Eject and re-insert the disc into the radio. This method will restart the media from the beginning. 3. For NAV unit radios - press play on the CD/DVD tab. Disclaimer Page 12277 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Left Rear of the Engine Compartment Components Page 6544 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 2191 Window Switch - Right Rear (Crew Cab with A31/Extended Cab with ABV) Page 8310 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 20506 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3104 Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 4997 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 12037 Page 2776 Fuse: Application and ID Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 18676 Rear Seat Cushion Frame Replacement (Crew Cab with A68) Rear Seat Cushion Frame Replacement (Crew Cab with A68) Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 16932 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to theMaster Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 5817 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform theDiagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Modules connected to the low speed GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules when the ignition switch is in any position other than OFF. The low speed GMLAN serial data circuit uses JX 221, JX 339, and, if equipped, JX 223 as common connection points between some modules and the data link connector (DLC). Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication Page 12510 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 9085 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 13203 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 12754 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 16359 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 18744 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 14946 1 - Dome/Reading Lamp - Rear 2 - Electronic Compass Module (YE9 with CF5) 3 - Electronic Compass Module (YE9 except CF5) 4 - Inside Air Temperature Sensor (CJ2) Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 10524 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13493 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4859 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 8861 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 9025 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 18557 Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Page 809 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers Page 9918 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD and SHD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Inserts 12 - Transfer Case Shift Fork Spring 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case High/Low Shift Fork 15 - Transfer Case High/Low Shift Fork Inserts 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case Shift Detent Lever Assembly 18 - Transfer Case Rear Output Shaft 19 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 20 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 21 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 22 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Outer Page 11928 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 12335 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7461 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 11672 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 14179 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 14066 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Page 18802 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Locations Auxiliary Water Pump Relay: Locations Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 8785 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 19362 Page 16704 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Page 18231 Memory Seat Module (MSM) X3 (AN3) Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 13812 X113 Engine Jumper Harness to Engine Harness (Diesel) Page 17507 Locations Steering Wheel Heater Control Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 20983 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 15628 Page 19768 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 4015 4. Remove the CMP actuator (235) and timing chain (208). 5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Installation Procedure Page 12133 Junction Block - Rear Lamps X2 Page 5514 1 - Inflatable Restraint Roof Rail Module -Passenger (ASF) 2 - Data Link Resistor 2 (HP2) 3 - Seat Belt Pretensioner -Passenger Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) Page 3520 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass and additional 90 degrees using J 45059 . 9. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine Lubrication/Oil Pump/Service and Repair) . Page 4776 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11765 Page 10459 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Page 16949 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9281 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 18983 For vehicles repaired under warranty, use the table. Disclaimer Page 5711 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 19874 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Page 11395 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 10161 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 19450 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13736 Page 5124 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 14990 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 15638 Disclaimer Page 18770 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 9409 8. Place an alignment mark between the pinion and the pinion yoke. Note DO NOT reuse the pinion nut, replace with NEW. 9. Using the J 8614-01 - holder and remover , remove and discard the pinion the pinion nut. Note Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Page 492 Control Module HVAC: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 13239 Junction Block - Right I/P X2 Page 20394 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 12217 Fuse Block - Auxiliary X2 (HP2) Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 18093 Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 16492 Disclaimer Page 4795 Page 6531 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 16968 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 11501 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 7110 Component Parts Page 7377 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 8858 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Power Brake Booster Vacuum Check Valve and Hose Replacement Page 4086 Water Pump: Diagrams Component Connector End Views Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 13006 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 20942 Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement (1500) Page 5622 Page 14195 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 14791 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 13561 Junction Block - Left I/P X12 (except MEX) Page 18564 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 7081 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. If replacing the right side spark plug(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug(s) through the wheel opening. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 2. If replacing the right side spark plug(s), perform the service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 3. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Driver or Passenger Seat Back Cushion Heater Replacement Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Page 7751 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 18764 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Body Hinge Pillar Trim Panel Replacement Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Page 4463 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 19990 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 5854 7. If all circuits test normal, replace the IPC. Repair Instructions Perform theDiagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM replacement, setup, and programming Page 6481 9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. Page 11019 Page 9564 Drive/Propeller Shaft: Symptom Related Diagnostic Procedures Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation) . Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer toDiagnostic Starting Point - Vibration Diagnosis and Correction (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Diagnostic Starting Point - Vibration Diagnosis and Correction) . Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Knock or Clunk Noise Knock or Clunk Noise Leak at Front Slip Yoke Leak at Front Slip Yoke Page 19356 Devices and Sensors Page 15382 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Page 5762 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 8256 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7152 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 13046 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11447 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Page 2965 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 3521 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . 2. Remove and discard the CMP actuator solenoid valve. Installation Procedure Page 13426 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 9472 Note If the rear axle shaft is difficult to remove, proceed to step 14. 13. Remove the rear disc brake axle shaft (1) from the rear axle assembly (2), if equipped 14. Using the J 2619-01 - hammer (2) and the J 45859 - remover/installer (1), remove the rear axle shaft from the rear axle assembly. 15. Replace the rear axle shaft seal and or bearing, if needed. Refer to Rear Axle Shaft Seal and/or Bearing Replacement (See: Axle Bearing/Service and Repair/Rear Axle Shaft Seal and/or Bearing Replacement) . Installation Procedure Note When installing the rear axle shaft, ensure that the seal is not damaged. Page 8487 Caution: Use care when handling the control valve body assembly. If dropped, damage to the control solenoid valve body assembly internal components, including the transmission control module (TCM), may result. Caution: Discard the channel plate. Replace with a NEW channel plate. Reusing an old channel plate may cause damage to the control solenoid valve assembly. Note Use care when installing the channel plate assembly. However, if a retaining tab is broken or missing, DO NOT replace the control solenoid valve assembly. The channel plate assembly can still be adequately aligned. 1. Install the control valve channel plate spacer plate gasket (1). 2. Install the transmission wiring harness assembly (2). 3. Install the control solenoid valve and TCM assembly (4). Note Page 20597 Sliding Rear Window Close Relay (A48) Page 6124 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Page 4437 Drive Motor Generator Battery Control Module X3 (HP2) Page 20065 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 9071 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 4582 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Drive Motor Generator Power Inverter Module X5 (HP2) Page 8301 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 5307 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Actuator: Locations Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) 1 - Output Shaft 2 - Pinion Bearing Spacer 3 - Pinion Head Bearing Assembly 4 - Pinion Shim 5 Stem Pinion 6 - Pinion Flange Nut 7 - Pinion Flange Washer 8 - Pinion Flange Assembly 9 - Pinion Seal 10 - Pinion Tail Bearing Assembly 11 - Carrier Housing 12 - Output Shaft Seal Assembly 13 Output Shaft 14 - Drain Plug Assembly 15 - Drain Plug Washer 16 - Fill Plug Assembly 17 - Fill Plug O-ring Seal 18 - Carrier Locator Pin 19 - Vent Connector 20 - Differential Case 21 - Ring Gear 22 - Output Shaft Bearing Assembly 23 - 8-Point Lock Ring 24 - Sleeve and Insert Assembly 25 Differential Side Bearing Assembly 26 - Differential Cross Pin Lock Page 12886 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 17194 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 8161 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Page 11903 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 10346 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 3491 4. Remove the valve lifter oil manifold bolts (2). 5. Remove the valve lifter oil manifold (1). Note Remove only the outer gasket from the manifold. Do not disassemble any of the internal components of the manifold in an attempt to remove the 8 inner sealing gaskets. If the inner gaskets are cut or damaged, replace the manifold as an assembly. Only use a wire-cutter type tool in order to minimize the amount of debris. Do not use a rotary-type cutting tool on the retaining straps. 6. Identify the 8 gasket retaining strap locations (1-8). Page 17174 Disclaimer Page 17343 Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Page 2239 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Page 11209 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 4033 Fuel System Diagnosis (W/FPCM) Fuel System Diagnosis (w/FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Important: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Ignition OFF, all accessories OFF, install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . Page 17150 Page 7762 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 11270 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling) . 7. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Parking Brake Rear Cable Replacement - Right Side (JD9) Parking Brake Rear Cable Replacement - Right Side (JD9) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Page 6476 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 19. Install the fuel fill cap. 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Evaporative Emission Line Replacement - Chassis (Regular Cab) Evaporative Emission Hose/Pipe Replacement - Chassis (1500 Regular Cab) Removal Procedure Page 4043 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct (3) from the throttle body and MAF/IAT sensor. Installation Procedure Note Ensure that the notch in the air cleaner outlet duct throttle body aligns with the boss on top of the throttle body. 1. Install the air cleaner outlet duct (3) to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 7860 Switches and Relays Page 11521 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 13501 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 15413 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 11940 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 6735 4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid (3). 5. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 6. Remove the connector position assurance (CPA) retainer (2). 7. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 8. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 9. Remove the engine wiring harness clip (4) from the ignition coil bracket stud. Page 17342 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Page 7868 Page 8711 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 3899 28. Remove and discard the intake manifold gaskets (514). 29. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection (See: Service and Repair/Overhaul) . 30. Remove the upper intake manifold cover nut. 31. Remove the upper intake manifold cover. Locations Seat Heater Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 12921 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 7307 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 12539 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Endgate Cable Replacement Tailgate Shock / Support: Service and Repair Endgate Cable Replacement Endgate Cable Replacement Page 6031 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 7323 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Fuse Block - Auxiliary Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 18830 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8316 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 20460 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 2861 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 9341 For vehicles repaired under warranty, use the table above. Disclaimer Page 15992 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Page 17585 Hood Hinge: Service and Repair Hood Link Replacement Hood Link Replacement Page 1679 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 7867 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 19639 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Component Locations Courtesy Lamp: Component Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 1452 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 9574 5. Reference mark the transmission or the transfer case (1), propeller shaft flip yoke (2), universal joint bearing cap (3), and the propeller shaft (4). 6. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with clean grease or transmission fluid. Page 13599 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 2703 HEADLINER 3 ..................................................................................................................................... ........................... Headliner Harness Connector 3 HEADLINER 2 ...................................................... .......................................................................................................... Headliner Harness Connector 2 HEADLINER 1 ..................................................................................................................................... ........................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Page 9254 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Page 11267 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the park brake cable clip bolt. Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling) . 7. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Parking Brake Rear Cable Replacement - Left Side (JF3, JF7) Parking Brake Rear Cable Replacement - Left Side (JF3, JF7) Page 19838 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 1846 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 6488 17. Remove the caps from the fuel rail and EVAP line. 18. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 19. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 20. Install the fuel fill cap. 21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 22. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 23. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Evaporative Emission Line Replacement - Chassis (Extended/Crew Cab With 8 Ft Bed Evaporative Emission Hose/Pipe Replacement - Chassis (1500 Extended/Crew Cab w/8 Ft Bed) Removal Procedure Page 17544 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Service and Repair Engine Oil Control Valve: Service and Repair Oil Pressure Relief Valve Replacement Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement (4WD) (See: Oil Pan/Service and Repair)Oil Pan Replacement (2WD) (See: Oil Pan/Service and Repair) . 2. Place the oil pan on a clean work surface. 3. Remove the oil pressure relief valve (455) and washer. Installation Procedure 1. Inspect the NEW oil pressure relief valve for proper operation. Lightly depress the ball (2). The valve spring (1) should seat the ball to the proper closed position. 2. Install the NEW oil pressure relief valve (455) and washer. Page 9037 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 7956 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13155 Page 15557 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 10297 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 5787 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 13553 Junction Block - Left I/P X3 (except MEX) Page 11327 The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. Warning Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 4. Place the J-26889 - Accumulator Piston Compressor over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). Page 9609 14. Position the slip yoke (1) in the propeller shaft (2). 15. Position the universal bearing (1) in the yoke of the propeller shaft (2). 16. Center the universal spider in the universal bearing. 17. Press the universal bearing into the yoke. 18. Install the retaining ring (2) in the propeller shaft yoke (1). 19. Rotate the propeller shaft and repeat steps 8-11 or the opposite universal bearing. Page 10090 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 18157 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Page 7162 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 1941 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 11366 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control module electrical connector. Note It is not necessary to completely remove the bolts. 4. Reach above the trailer brake control module and relay bracket and loosen, but do not remove, the trailer brake control module bolts (1). Page 2945 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 6399 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 13807 Page 8703 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 15237 A/C Refrigerant Pressure Sensor (HP2) Component Locations Accelerator Pedal Position Sensor: Component Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (5.3L/6.0L Except LY6) Page 11449 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Page 1200 Page 17959 Door Lock Cylinder: Service and Repair Rear Door Lock Cylinder Replacement Endgate Lock Cylinder Replacement Page 16093 Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Procedures Wiper Blade: Procedures Wiper Blade Element Cleaning 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20233 Page 16437 Auxiliary Input / Output Jack: Diagrams Component Connector End Views Audio/Video Adapter (U42) Page 10156 7. Remove the range selector lever nut (1). 8. Remove the range selector lever (2). Installation Procedure 1. Install the range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the range selector lever nut (1). Tighten the nut to 25 Nm (18 lb ft). Component Locations Air Bag Control Module: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 2026 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 18054 1 - Door Frame 2 - Door Lock Switch -Driver (AU3) 3 - Speaker -Left Front 4 - Door Latch -Driver Driver Door Components (AN3/DL3) Page 6146 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 4636 1. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 2. Lift the drive motor generator control module assembly into the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Remove the lifting device and install the ball studs (1). Tighten the ball studs to 10 Nm (89 lb in) . 4. Install the drive motor generator control module assembly retainers (4) and mounting nuts (3). Tighten the mounting nuts to 9 Nm (80 lb in) . 5. Install the APM ground strap (1) and APM ground strap nut (2). Tighten the nut to 9 Nm (80 lb in) . Page 2029 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Electronic Traction Control Switch Replacement Page 3600 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13883 X700 Left Rear Door Harness to Body Harness (Extended Cab) Page 5824 * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform theDiagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Control Module References (See: Testing and Inspection/Programming and Relearning)for control module replacement, setup, and programming Page 86 Communications Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 372 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Page 20050 Locations Hazard Warning Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 6777 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Regular Cab) Fuel Hose/Pipes Replacement - Chassis (1500 Regular Cab) Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 5504 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 6206 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Page 10959 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut toward the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement) . 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 5. Lower the vehicle. Page 16696 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 16099 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 19641 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 17085 Symptoms - Cruise Control Cruise Control: Testing and Inspection Symptoms - Cruise Control Symptoms - Cruise Control Important: The following steps must be completed before using the symptom tables. 1. Before using the symptom diagnostic table, perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) , in order to verify the following conditions: * There are no DTCs set. * The module can communicate via the serial data link. 2. Review the system operation in order to understand the system functions. Refer to Cruise Control Description and Operation (See: Description and Operation) . Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the cruise control system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics) . Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Cruise Control Malfunction (See: Cruise Control Malfunction) * Cruise Control Indicator Malfunction (Switch Indicator Malfunction) (See: Cruise Control Indicator Malfunction (Switch Indicator Malfunction) )Cruise Control Indicator Malfunction (IPC Indicator Malfunction) (See: Cruise Control Indicator Malfunction (IPC Indicator Malfunction)) Page 19700 Fuel Pump and Sender Assembly - Rear (LY6 with MEX without NQZ) Page 10389 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 6060 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Disengage the engine wiring harness electrical connector retainers and remove the connectors (2) from the ECM (1). Page 7416 Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF/NQH) Page 2771 Fuse Block - Underhood X5 Page 13611 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 6453 4. Remove the vent solenoid hose and filter (2). 5. Replace the vent hose with bulk 5/8 in heater hose. Installation Procedure 1. Use a hose clamp (1) at the end of the vent hose. 2. Ensure the filter (3) points down. 3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4). 4. Secure the remaining portion of the vent hose along the frame with tie straps as needed. 5. Position and install the evaporative canister vent solenoid (1) to the vehicle. 6. Secure both ends with hose clamps (2). Page 16610 Memory Seat Module (MSM) X5 (AN3) Page 4229 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Brake Master Cylinder Pressure Sensor Replacement Brake Hose/Line: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Note Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. Page 3087 Fuse Block - Underhood X6 Page 1021 Transmission Control Module (TCM) (MW7) Page 12328 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4852 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10769 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Page 9420 2. Install the ring gear to the differential case. Note Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the NEW ring gear bolts and tighten to 120 Nm (89 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement) . 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle) )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 8. Remove the support and lower the vehicle. Page 4897 Page 7310 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 13723 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (4.8L/5.3L/6.0L/6.2L) Page 11759 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 19531 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 9014 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 5774 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 4454 Locations Steering Mounted Controls Assembly: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 2640 Page 18235 Memory Seat Module (MSM) X7 (AN3) Page 8729 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Page 8675 For vehicles repaired under warranty, use the table. Disclaimer Page 20257 Page 10767 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 7456 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 2178 Door Lock/Window Switch - Driver X4 (AN3) BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 3. Remove the fill plug. 4. Remove the drain plug. Note Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Page 15229 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 4868 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Locations Vehicle Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 6373 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 20350 Page 18662 Seat Cushion: Service and Repair Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Page 5462 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 17818 * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) Page 20207 Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 8713 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 2848 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Page 6440 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Generator Control Module Ground Strap Replacement Drive Motor Power Cable: Service and Repair Generator Control Module Ground Strap Replacement Generator Control Module Ground Strap Replacement Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Removal Procedure 1. Remove the air cleaner assembly. Refer to Upper Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the drive motor generator control module ground strap bolt (1) and strap (2). Installation Procedure Page 4487 IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 7674 Disclaimer Page 6938 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. Caution: DO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control. Page 6257 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 4733 Drive Motor Temperature Sensor: Diagrams Component Connector End Views Generator Control Module Temperature Sensor (HP2) Generator Battery Vent Fan (HP2) Page 12080 Fuse Block - Underhood X3 Page 14032 IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Disclaimer Page 14982 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. If equipped, remove the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. 6. Remove the blower motor. Installation Procedure 1. Install the blower motor. Page 7476 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 5737 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 3553 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7345 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 5277 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 11648 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Page 16569 Disclaimer Page 19078 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Remove the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, reposition the engine wiring harness sleeve (3). 3. Disconnect the engine wiring harness electrical connector (4) from knock sensor. 4. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 2682 Page 12631 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Page 7278 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5589 Page 9390 Note Step 5 is for those vehicles equipped with the 9.5 LD inch axle. 5. Using the J 22912 - remover and a press, remove the differential pinion bearing. 6. Remove the shim (1). Page 4631 Drive Motor Control Module: Service and Repair Drive Motor Generator Control Module Assembly Replacement Drive Motor Generator Control Module Assembly Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 3. Disconnect the drive motor generator control module assembly connector (1). 4. Drain the power electronics cooling system. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . Page 7985 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 20287 Page 5806 Page 10372 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 2692 Fuse Block - Underhood X6 Page 18454 Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 2232 Page 12762 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 1541 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 9076 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18839 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 20247 Page 19578 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 4925 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 9275 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Page 12440 Junction Block - Left I/P X7 (JF4) Page 9087 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 19980 Center Mounted Brake Lamp: Service and Repair High Mount Stop Lamp Replacement (Regular Cab) High Mount Stop Lamp Replacement (Regular Cab) Page 13617 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 11899 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Interior - Seat Memory Inopertive After Air Bag Deploys PROM - Programmable Read Only Memory: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17238 Body Control Module (BCM) X7 (Except MEX/A52) Page 19420 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 13847 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 4141 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 9356 3. Remove the lower differential carrier assembly bushing by performing the following steps: 1. Install the J 21474-18 (1), the thrust bearing (2), the J 33791-1 (3), the J 36616-2 (4), and the forcing screw as shown. 2. Remove the lower differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18. Installation Procedure 1. Install the lower differential carrier assembly bushing by performing the following steps: 1. Install the J 21474-18 (1), the thrust bearing (2), the J 36616-2 (3), the J 36616-1 (4), and the forcing screw (5) as shown. 2. While holding the forcing screw, slowly tighten the J 21474-18 until the bushing has stopped against the step on the bushing and is centered within the differential carrier assembly bushing bore. Page 5403 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 7718 Devices and Sensors Page 15210 Tighten the bolts to 4 Nm (35 lb in). 5. Connect the electrical harness and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel. Refer to Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 8. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 9. Install the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Battery Replacement) . 10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) () . 11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 8959 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 19629 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 4238 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Interior - Lint Accumulation On Ebony Colored Seats Head Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 9456 12. Lower the vehicle. Page 20067 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Page 1917 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 10905 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 6308 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 10771 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 12. Lower the vehicle. Page 4785 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 20773 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1044 Disclaimer Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 11957 Branching Point: Diagrams JX339 Splice Pack Connector End Views JX339 (Except MEX) Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 16305 Page 19528 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 11834 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 19197 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Locations Battery Current Sensor: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Page 17657 For vehicles repaired under warranty, use the table. Disclaimer Page 11216 Disclaimer Page 13545 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 13042 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 14269 Power Steering Motor: Service and Repair Power Steering Assist Motor Replacement Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. Note The wiring harness protective cover is intended to keep the wiring harness connectors contaminant free. Do not remove the protective cover from the power steering wiring harness extension harness connectors until the harness has been routed to the correct position. 1. Perform the high voltage disabling procedure. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Note The power steering assist motor harness is not repairable. Only replace the harness and never attempt to repair it. 3. Release the power steering assist motor electrical harness connector position assurance tab (3). The connector in the graphic is shown upside down for clarity. 4. Press down on the connector cam lever lock tab (2). Note The connector will back off of the electronic power steering control module smoothly as the connector cam lever moves towards it. Do not pull on the Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: Customer Interest Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 1889 Right Side of the Engine Components (Diesel) 1 - Fuel Injector 7 2 - Fuel Injector 5 3 - Fuel Injector 3 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Fuel Injector 1 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 7 - Intake Air Valve 8 - Crankshaft Position (CKP) Sensor 9 - Glow Plug 1 10 - G103 11 - G105 12 - Block Heater 13 - Glow Plug 3 14 - Glow Plug 5 15 - Water In Fuel Sensor 16 - Starter Motor 17 - Glow Plug 7 Rear of the Engine Components (Diesel) Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Locations Towing Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 11546 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 17233 Body Control Module (BCM) X3 Page 20572 Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Motor (A48) Page 2281 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 11874 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 16316 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . Page 5687 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 12243 Junction Block - Right I/P (Wire Entry) Page 12405 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 2842 Junction Block - Left I/P X9 (except MEX) Page 483 Page 11812 Harness Components Page 13163 Fuse: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 1835 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 4. Remove the HO2S (3). Installation Procedure Page 9408 Pinion Flange: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement) . 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . Note The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . Note Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with a two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . Note Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. Page 6892 Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 8296 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 2033 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . Page 4981 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 12527 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 10754 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Component Locations Power Seat Switch: Component Locations Passenger Seat Components - 1 of 2 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 14921 Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Page 14991 Blower Motor: Diagrams Component Connector End Views Blower Motor Blower Motor Control Module X1 Page 2935 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 17032 Page 140 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 5513 1 - Inflatable Restraint Roof Rail Module - Driver (ASF 2 - Rear Window Defogger Grid (C49) 3 Seat Belt Pretensioner - Driver Right Side of the Passenger Compartment Components (Extended/Crew Cab) Page 15235 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Low Pressure Sensor (HP2) A/C Low Pressure Switch Page 2176 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 8116 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 724 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Rear of the Engine Compartment Components Page 10957 Page 20264 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Page 553 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 19534 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 20436 Page 11409 1. Position the EBCM (1) to the BPMV. 2. Push the EBCM squarely onto the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the EBCM bolts (1) and tighten in a cross pattern to 3 Nm (27 lb in) . 4. Connect the EBCM electrical connector. 5. If installing a new EBCM, the EBCM must be programmed and the sensor and boost valve calibration and EBCM learn processes must be performed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 12358 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 18620 Disclaimer Page 976 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 8134 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 12246 Junction Block - Right I/P X2 Page 4632 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 5. Remove the drive motor generator power inverter control module (PIM) 3 phase cable terminal fasteners (1). Caution: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper: * Cable sealing * Electrical shielding * Terminal position assurance 6. Remove the PIM 3 phase cable mounting fasteners (2, 4). 7. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box. 8. Remove and discard the seals (6). Page 13433 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 11089 18. Through the frame crossmember, remove the BPMV bracket bolts (1). 19. Loosen, but do not remove, the lower BPMV bracket bolt (1). Page 10210 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 3077 Page 1661 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 12949 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 7810 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11948 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 1213 For vehicles repaired under warranty, use the table. Disclaimer Page 5954 Body Control Module (BCM) X5 Page 11906 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 10096 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 18878 Seat Heater: Symptom Related Diagnostic Procedures Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: The following steps must be completed before using the symptom tables. 1. Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation/Heated Seats Description and Operation) . Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics) . Symptom List Refer to Heated Seat Inoperative (See: Heated Seat Inoperative) in order to diagnose the symptom. Heated Seat Inoperative Heated Seat Inoperative Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The driver and front passenger heated seats are controlled by separate heated seat switches located on the door panels. When a heated seat switch is pressed, ground is momentarily applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial message to the memory seat module (MSM) indicating the heat seat request. The MSM then applied battery voltage to the seat cushion and seat back heater elements through a common voltage supply circuit. Each individual heater element is grounded by the module through separate low side drive control circuits. The heater element control circuits are pulse width modulated (PWM) to ground by the module in order to control the seat temperatures by regulating the current flow through the heater elements. The MSM relies on 4 independent inputs from temperature sensors (thermistors) located in the seat back and seat cushion of the driver and passenger seats. The temperature sensor resistance varies based on the temperature of the heating element causing the signal circuit voltage to change. Once the seat reaches the switch set temperature, the MSM will then cycle the control circuits of the heating elements ON and OFF in order to maintain the desired seat temperature based on the feedback voltage from the sensors. The MSM then monitors the current flow through the heating elements and the of rate change of the temperature sensor to verify correct heated seat operation. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 2971 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3971 3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway. 4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange. Page 11612 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 12081 Page 12261 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel I/P Harness Routing - Engine Compartment (Except HP2) Page 20516 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Service and Repair Steering Damper: Service and Repair Steering Linkage Shock Absorber Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Note Discard the steering linkage shock absorber nut. 2. Remove the steering linkage shock absorber nut (1) from the steering linkage shock absorber (2). 3. Remove the steering linkage shock absorber from the relay rod using pullerJ 24319-B . Page 19679 Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Average Fuel Economy (AFE) * Average Speed (AVS) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/Active Fuel Management (Displacement on Demand (DOD)) * Odometer * Trans Temp * Trip Odometer * Trip Time * Total Fuel Saved (Hybrid) * Fuel Saved Since Reset * Compass * Outside Air Temperature * Blank Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu * Engine Hours * Compass * Outside Air Temperature * Side Obstacle Detection Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language Page 3983 5. Compress the timing chain tensioner guide and install the EN 46330 . 6. Install the timing chain tensioner (232) and bolts (231). Tighten the bolts to 25 Nm (18 lb ft). Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 15205 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Body - Incorrect Sun Visor Label Child Seat: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 12962 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17229 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: Customer Interest Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 6170 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 9230 343 - Control Valve Upper Body Assembly Page 19516 Page 4796 Body Control Module (BCM) X5 Page 14978 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 8976 Switch Position Icons Page 13194 Page 2073 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 15704 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended Cab with 10 Series with ASF) Page 12502 Fuse Block: Service and Repair 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Page 19993 1 - X320 2 - Rear Window 3 - J336 (except C49) 4 - J335 (except C49) Left and Right Hip Lamp Harness Routing (R05) Page 4126 Radiator Cooling Fan Resistor: Diagrams Component Connector End Views Engine Cooling Fan Resistor - Left (HP2) Engine Cooling Fan Resistor - Right (HP2) Page 18455 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 6442 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4416 Battery Current Sensor: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 12319 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 5038 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Page 10201 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1804 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 13754 X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X224 Page 11360 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Fuse Block - Auxiliary Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 3210 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in) . Note Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 6571 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 14169 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 19536 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Specifications Firing Order: Specifications Ignition System Specifications Page 7357 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 7028 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 11137 Master Cylinder Reservoir Replacement (J92) Master Cylinder Reservoir Replacement (Two-mode Hybrid) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Note During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container. 4. Disconnect the brake fluid level sensor electrical connector. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8147 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Underhood Fuse Block Fuel Pump Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood Label Page 12032 Fuse Block - Underhood Bottom View Page 12600 Page 11088 15. Disconnect the primary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 16. Disconnect the right supply brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 17. Disconnect the left supply brake pipe fitting (2). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 13036 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 6075 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 12963 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 17318 Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Page 2179 Door Lock/Window Switch - Driver X7 (AN3/DL3) Page 5347 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 11340 Page 12371 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2977 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Center Pillar Assist Handle Replacement Passenger Assist Handle: Service and Repair Center Pillar Assist Handle Replacement Center Pillar Assist Handle Replacement Page 854 Page 9868 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 10317 Component Parts Page 20627 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 Nm (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module . 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Tighten bolt to 11 Nm (97 lb in). 6. Install the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 7. Inspect the rear sliding window for proper operation. Page 10666 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 20541 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 6260 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 14042 For vehicles repaired under warranty, use the table. Disclaimer Page 10054 Disclaimer Page 8432 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 8049 Page 7569 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Diagrams Neutral Safety Switch: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 19380 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 5140 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (6.0L with ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.3L) Page 19387 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 10635 Input Speed Sensor (ISS) (M30) Page 6527 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 4989 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor Replacement Page 15515 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 2690 Fuse Block - Underhood X5 Page 15468 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 1190 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 213 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 13993 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3744 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 12177 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Page 659 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 5029 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Engine - Valve Lifter Tick Noise At Start Up Oil Filter: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 8812 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13147 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 12301 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 12608 X113 Engine Jumper Harness to Engine Harness (Diesel) Page 6420 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 11688 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 9285 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Page 13739 X176 Inline Harness Connector End Views Page 8320 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 17832 Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Blower Motor Control Module Control Module HVAC: Diagrams Blower Motor Control Module Component Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 8229 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 2917 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 17739 For vehicles repaired under warranty, use the table above. Disclaimer Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Unbolt the front propeller shaft from the front differential, if equipped with four wheel drive (4WD). Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 3. Remove the connector position assurance (CPA) retainer (4). 4. Disconnect the engine wiring harness electrical connector (7) from the HO2S. 5. Remove the HO2S electrical connector clip (6) from the fuel line clip. Page 8750 Switches and Relays Page 15285 HVAC Control Module X3 (C67/C42/CJ2/MEX) Page 12423 Fuse Block - Auxiliary X2 (HP2) Page 15696 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 - X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp clip (2) from the air cleaner outlet duct (1). Page 15985 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended/Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Page 19469 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Page 19820 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 4798 Body Control Module (BCM) X7 (Except MEX/A52) Page 7123 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 11488 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 8313 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 4072 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 575 Page 12697 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Page 18671 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Page 16859 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 11665 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 10360 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 9058 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 12769 Page 2241 Alignment: Testing and Inspection Trim Height Inspection Note Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) . * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Page 13709 Front Side Door Inside Handle Replacement (with SLT) Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (with SLT) Front Side Door Inside Handle Replacement (with SLT) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 6106 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 15011 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Page 17764 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7187 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 8719 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 4537 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 9. Remove the HV dc electric air conditioning compressor module (ACCM) cable terminal fasteners (1). 10. Remove the HV dc electric ACCM cable mounting fasteners (3). 11. Remove the HV dc electric ACCM cable (4) from the PIM distribution box. 12. Remove the HV dc battery cable terminal fasteners (2). 13. Remove the HV dc battery cable mounting fasteners (5). 14. Remove the HV dc battery cable (6) from the PIM distribution box. 15. Inspect and retain the seals (7). 16. Remove the drive motor generator position sensor shield circuit fastener (2). 17. Remove the shield circuit harness (1). 18. Remove the PIM cooling inlet (4) and outlet (5) hoses. 19. Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle. Page 10136 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 5210 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 19488 Cruise Control: Testing and Inspection Cruise Control Indicator Malfunction (Switch Indicator Malfunction) Cruise Control Indicator Malfunction (Switch Indicator Malfunction) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The cruise control switch contains an LED that illuminates to indicate the cruise control system has been switched ON. Voltage is applied through the ON/OFF switch to the LED when the switch is pressed. The BCM provides the ground path for the LED through a dedicated control circuit. Pressing the switch again opens the switch and the lamp turns OFF. Reference Information Schematic Reference Cruise Control Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Cruise Control Description and Operation (See: Description and Operation) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, observe the cruise control indicator while applying the cruise On/Off switch. The indicator should turn on and off accordingly with the applied switch. Circuit/System Testing Important: Refer to DTC B3794 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/B Code Charts/B3794) before performing this diagnostic, if this code is set as current or history. Page 13386 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 7759 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 20223 Page 18947 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 18866 Heated Seat Element - Passenger Cushion (AN3 without KB6) Page 20899 2009 Chevrolet Traverse 2007-2009 GMC Acadia 2007-2009 Saturn OUTLOOK 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood bussed electrical center (UBEC) is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Note Remove the two relays next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in Page 20443 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 15728 When in the correct location, the latch plate tongue will be between the webbing and the seat. U.S. dealers: For additional information, search gmtraining.com's Web Video Library for the May 2007 Emerging Issues video (course #10207.05D). Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11240 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 15602 Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 8853 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. Page 18619 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 16335 Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Page 1543 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 10808 Page 3078 Fuse Block - Underhood X2 Page 1355 Wheel Speed Sensor (WSS) - Right Rear (JL4/HP2) Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 11075 Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3, w/JL4) Component Locations Power Window Switch: Component Locations Door Component Views Left Rear Door Components (Extended Cab) 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Page 12059 Fuse Block - Auxiliary X1 (HP2) Page 15476 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Page 14993 Page 10951 Page 5791 Page 9398 2. Using the J 22761 - installer (1) and the J 8092 - driver (2), install the drive pinion gear pilot bearing in the differential housing (3). 3. Using the J 37624 - installer (2) and the J 8092 - driver (1), install the inner pinion bearing cup in the pinion gear bearing retainer. 4. Using the J 8608 - installer (2) and the J 8092 - driver (1), install the outer pinion bearing cup in the pinion gear bearing retainer. Page 13557 Junction Block - Left I/P X8 (except MEX) Page 15113 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 16502 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 18245 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 11872 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) orRear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair ) 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Page 17571 9. Remove the cable ends (1) from the window guide (2) at each end of the window. 10. Remove the regulator (1) and cables (2) from the vehicle. Installation Procedure Page 13185 Page 7955 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 10262 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7176 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 15023 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Page 12433 Page 6070 Page 17142 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 4948 Page 12213 Fuse Block - Auxiliary (HP2), Top View Page 7999 Actuator: Diagrams Component Connector End Views Front Drive Axle Actuator (NQF/NQG/NQH) Page 11547 Auxiliary Battery Relay: Connector Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxilary Battery Relay 5 - X122 Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure 1. Remove the rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Left Side) or Valve Rocker Arm Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Cover Replacement - Right Side) . Note The engine firing order is 1, 8, 7, 2, 6, 5, 4, 3. Cylinders 1, 3, 5 and 7 are the left bank. 2. Remove the number one cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair) . Note Place the rocker arms, pushrods, and pivot support, in a rack so that they can be installed in the same location from which they were removed. 3. Remove the rocker arm bolts. 4. Remove the rocker arms. 5. Remove the rocker arm pivot support. Page 12948 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 6832 Fuel Gauge Sender: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Page 2805 Fuse Block - Underhood X1 Page 4650 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in) . 4. Rotate the drive motor generator control module assembly onto the APM. 5. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 6. Plug the remaining coolant pipe with GE-48494 adapter kit plug and clamp (1). 7. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 8. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seals. * If pressure remains at the specified value, proceed to the next step. 9. Remove all GE-48494 - adapter kit components. Page 11621 1. Install the battery tray (3) into the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the battery tray to battery tray reinforcement bolts (1) and tighten to 9 Nm (80 lb in) . 3. Install the battery tray support bolts (2) and tighten to 9 Nm (80 lb in) . 4. Install the battery tray to auxiliary BEC bolt (4) and tighten to 9 Nm (80 lb in) . 5. Install the positive and negative battery cables. 6. Install the battery. Refer to Battery Replacement (See: Service and Repair/Battery Replacement) . Page 12148 Page 20898 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 HUMMER H2 1. Open the hood and disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. 4. Remove the two relays next to the fuse to gain access to the fuse. 5. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 6. Discard the 60 amp heated windshield washer fuse. 7. Install the two relays removed in Step 4. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Buick Enclave Page 5673 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 1760 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 5808 The data link connector (DLC) is a standardized 16-cavity connector. The DLC low speed serial data circuit is connected directly to the instrument panel (I/P) splice then to all other splices or modules. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 GMLAN low speed communications terminal * Pin 4 scan tool power ground terminal * Pin 5 common signal ground terminal * Pin 6 high speed GMLAN serial data bus (+) terminal * Pin 14 high speed GMLAN serial data bus (-) terminal * Pin 16 scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No COMM for that options specific control module. In order to avert misdiagnoses of No Communication with a specific module, refer toData Link References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Data Link References) for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Page 10929 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 18812 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 4637 6. Install the sight shield circuit breaker (2) and secure with bolts (1). Tighten the bolts to 5 Nm (44 lb in) . 7. Connect the APM assembly connectors (1 and 3) and install any removed locking tabs. 8. Connect the APM assembly connector (2) using the following procedure: 1. Push the lever up. Note Install the connector (2) without disturbing the position of the lever. DO NOT use the lever to install the connector in place. 2. Install the connector (2) onto the terminals by pushing on the connector only. 3. Rotate the lever after the terminals are engaged. 4. Push the green tab to lock the lever. Page 3418 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 9. Remove the safety stands. 10. Lower the vehicle. Page 12127 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 12378 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 3046 Junction Block - Left I/P X7 (JF4) Page 13285 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Page 20772 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Procedures Fuel Injector: Procedures Fuel Injector Cleaning Special Tools * J 37287 Fuel Line Shut-Off Adapters * J 35800-A Fuel Injector Cleaner * J 42873-1 3/8 Fuel Line Shut-Off Valve * J 42873-2 5/16 Return Pipe Shut-Off Valve * J 42964-1 3/8 Fuel Pipe Shut-Off Valve * J 42964-2 5/16 Fuel Pipe Shut-Off Valve Caution: * GM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. * Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank, as it may damage the fuel pump and other system components. * Do not exceed the recommended cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Note Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced. 1. ObtainJ 35800-A (2). Note Make sure the valve at the bottom of the canister (3) is closed. 2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. 3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail withJ 37287 , orJ 42964-1 , andJ 42964-2 orJ 42873-1 , andJ 42873-2 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes. Page 15700 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series Except ASF/MEX/Crew Cab) Page 13881 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views Page 17047 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Page 1020 Page 20960 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement Page 14053 Frame Angle Measurement (Express / Savana Only) ........ Page 2700 Fuse Block - I/P X4 Page 780 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 10683 Braking Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Piston Position Sensor (HP2) Page 8213 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 6676 3. Once installed, pull on both sides of the connection in order to ensure the connection is secure. 4. Install the fuel line retainer. Page 120 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20891 the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers/retailers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Note (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by June 8, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Note Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for the recall condition are handled by submitting a recall reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - submit as Net Item under the repair labor code. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Electrical - Various Rear Door Electrical Malfunctions Speaker: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 5704 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 8810 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12156 Fuse Block - Underhood X1 Page 2175 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) Page 10809 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Page 13416 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 1548 Page 2968 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 3091 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Specifications Luggage Rack: Specifications Fastener Tightening Specifications Page 6899 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 678 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10807 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Page 250 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13596 Page 19374 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14490 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 13358 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Page 11310 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Power Brake Booster Vacuum Sensor Replacement Removal Procedure 1. Disconnect the chassis wiring harness electrical connector (1) from the brake booster vacuum sensor. 2. Remove the brake booster vacuum sensor from the brake booster. 3. Remove the brake booster vacuum sensor grommet from the brake booster. Installation Procedure Important: Lightly coat the brake booster vacuum sensor grommet with clean engine oil before installing the sensor. Page 2697 Page 20360 Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement (GMC) Tail Lamp Bulb Replacement (GMC) Page 10613 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 7952 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 318 Memory Seat Module (MSM) X6 (AN3) Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to theMaster Electrical Component List (See: Locations/Component Locations) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 8546 3. Connect the auxiliary fluid pump control module electrical connector (1) to the engine wiring harness electrical connector (2). 4. Connect the auxiliary fluid pump electrical wire harness connector (1) to the auxiliary fluid pump control module connector (2). Page 3609 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 881 Steering Control Module: Diagrams Component Connector End Views Electronic Power Steering Motor Control Module X1 (HP2) Electronic Power Steering Motor Control Module X3 (HP2) Page 11764 Page 12036 Page 11701 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4543 15. Install the HV dc battery cable (6) with seal (7) into the PIM distribution box. 16. Install the HV dc battery cable mounting fasteners (5). Tighten the mounting fastener to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 17. Install the high voltage (HV) dc battery cable terminal fasteners (2). Tighten the terminal fastener to 9 Nm (80 lb in) . 18. Install the HV dc electric air conditioning compressor module (ACCM) cable (4) with seal (7) into the PIM distribution box. 19. Install the HV dc electric ACCM cable mounting fasteners (3). Tighten the mounting fasteners to 9 Nm (80 lb in) . Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 20. Install the HV dc electric ACCM cable terminal fasteners (1). Tighten the terminal fastener to 9 Nm (80 lb in) . 21. Install a new seal (3) on the PIM distribution box. Page 4951 Page 13788 Multiple Junction Connector: Diagrams X400 - X499 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Page 8947 Disclaimer Page 19426 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 2620 Fuse Block - Auxiliary (HP2), Top View Page 13281 Fuse Block - Underhood X5 Page 2795 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 9234 Note Do not tighten the bolts at this time. 4. Install by hand the control valve channel plate bolts (1). 5. Install the automatic transmission shift shaft position switch bracket (2). Note Do not tighten the bolts at this time. 6. Install by hand the control valve body bolts (1). Page 576 Page 3919 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the fuel rail bolts and tighten to 10 Nm (89 lb in) . 7. Install a NEW throttle body gasket to the intake manifold. 8. Install the throttle body. 9. Install the throttle body bolts/nuts and tighten to 10 Nm (89 lb in) . 10. Install the EVAP tube and purge solenoid. 11. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 11805 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Page 4499 Drive Motor Generator Battery Control Module X3 (HP2) Page 6890 A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 20941 Page 3041 Junction Block - Left I/P X2 (except MEX) Page 10082 Page 5549 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 10567 Page 15007 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Page 19947 Page 15114 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 5400 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 10676 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Page 18543 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Page 9494 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 16. Secure the small boot clamp (1) usingJ 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 5779 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 12602 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L and NQF/NQH) Page 6639 Fuel Injector 7 (4.8L/5.3L/6.0L/6.2L) Fuel Injector 7 (Diesel) Page 11785 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Body - Incorrect Sun Visor Label Sun Visor: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 15358 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Page 367 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 8634 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Locations Auxiliary Power Outlet: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 10278 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12618 X129 Inline Harness Connector End Views X129 I/P Harness to Chassis Harness (HP2) Rear Side Door Hinge Cover Replacement Rear Door Hinge: Service and Repair Rear Side Door Hinge Cover Replacement Rear Side Door Hinge Cover Replacement Page 315 Memory Seat Module (MSM) X3 (AN3) Page 6802 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 10246 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 9770 For vehicles repaired under warranty, use the table above. Disclaimer Steering/Suspension - Power Steering Fluid Leaking Power Steering Pump: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Page 15342 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 14898 Air Door Actuator / Motor: Service and Repair HVAC - Automatic Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Page 11575 4. Remove the negative battery cable ground terminal bolt (1) from the left side engine block boss. 5. Remove the negative battery cable (3) and the engine wiring harness ground (2) leads from the engine block boss. 6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 7. Remove the engine wiring harness ground lead bolt (1) from the frame. 8. Remove the engine wiring harness ground lead (2) and the negative battery cable lead (3) from the frame. 9. Lower the vehicle. Page 10514 Director, Customer and Relationship Services 09241 Page 6091 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 2081 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13473 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 19644 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 7758 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 17094 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 8297 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 8406 Director, Customer and Relationship Services 09241 Page 12975 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 5590 Engine Control Module (ECM) X1 (Diesel) Page 13873 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 11610 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 190 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 18791 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7180 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 20552 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 14048 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 18797 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13288 Fuse Block - Auxiliary (HP2), Bottom View Page 5629 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 10448 Page 6564 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 7329 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 429 6. Install the ABS module splash shield (1). 7. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . Page 2030 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 11905 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 1716 Disclaimer Page 3001 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 8575 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 1081 Page 19633 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 6455 4. Disconnect the vent solenoid hose from the plastic retainers (1). 5. Remove the vent solenoid hose. 6. Replace the vent hose with bulk 5/8 in heater hose. Installation Procedure 1. Use a hose clamp (1) at the end of the vent hose. 2. Ensure the filter (3) points down. 3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4). 4. Use 5/8 in heater hose and secure it along the frame with tie straps as needed. Page 8531 Disclaimer Page 1918 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 7961 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 505 HVAC Control Module X3 (C67/C42/CJ2/MEX) Page 12183 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 11074 Page 13560 Junction Block - Left I/P X11 (except MEX) Page 9447 Note Ensure the seal is fully seated in the hub bore. 9. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 10. Install the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 11. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note If the wheel hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the wheel hub seal must be replaced. 12. Install the wheel hub to the axle housing. 13. Using the J 2222-C - wrench , install the adjusting nut to the hub. 14. Adjust the wheel bearings. Refer to Wheel Bearing Adjustment (See: Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment ). 15. Install the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 16. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 17. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 11500 Page 564 Page 13700 1 - Door Frame 2 - X800 Right Rear Door Harness Routing (Crew Cab) Page 6493 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 Nm (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. If equipped with 2WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle. 10. Install the fuel/EVAP line bracket locator tab to the frame. 11. Install the fuel/EVAP line clips to the frame and crossmember. 12. Install the fuel/EVAP line bracket bolt (2). Tighten the bolt to 9 Nm (80 lb in). 13. Install the fuel/EVAP line clip nut (1). Tighten the bolt to 20 Nm (15 lb ft). 14. Remove the caps from the fuel and EVAP lines. 15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 10178 Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 13244 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 18730 Module Circuit Function Icons Page 9910 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 17698 Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (4WD 1500/2500) Page 1852 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Page 4288 2. Reinstall any loose boot. 16. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 17. Fully raise and support the vehicle. 18. Install the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar. Tighten the nuts to 50 Nm (37 lb ft). Partially lower the vehicle in order to work through the wheel opening. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair)Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair) . Page 19369 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 6661 16. Remove the engine wiring harness clip bolt (4) from the generator bracket. 17. Gather the branches of the engine wiring harness and reposition the aside. 18. Remove the positive crankcase ventilation (PCV) hose. Page 14774 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 5831 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 12194 Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 13213 HEADLINER 3 ..................................................................................................................................... ........................... Headliner Harness Connector 3 HEADLINER 2 ...................................................... .......................................................................................................... Headliner Harness Connector 2 HEADLINER 1 ..................................................................................................................................... ........................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Page 7462 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5941 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 3308 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Locations Auxiliary Water Pump Relay: Locations Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 19033 Seat Adjuster Switch - Passenger (AG2 without AN3) Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 14908 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Right Side Floor Air Outlet Duct Replacement - Right Side Page 11909 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13225 Junction Block - Left I/P X4 (except MEX) Page 3646 21. Position the generator control module 3 phase cables to the bracket channel. 22. Install the generator control module 3 phase cable clip to the tab (3) on the engine bracket (2). 23. Install the generator control module 3 phase cable clip nut (1). Tighten the nut to 9 Nm (80 lb in). 24. Enable the high voltage system. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . 25. Install the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . Page 16042 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 5331 Compression Check: Testing and Inspection Engine Compression Test Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. Note When performing an engine cylinder compression test for the RPO-LFA engine, note that this engine has a camshaft position actuator with a late intake valve closing feature and a 29 degree retard park position. With the actuator parked in a retard position, the effective compression of the engine is reduced during cranking. Compression values on the gage will be lower than a typical small block engine that does not have this feature. 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition key in the OFF position. 3. Charge the battery if the battery is not fully charged. 4. Disable the fuel and spark by removing the Fuel Pump relay and Powertrain relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) for the Fuse Block - Underhood Label. 5. Remove the spark plug wires from the spark plugs. 6. Remove all of the spark plugs. Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. 7. Install a compression gage to the cylinder to be tested. 8. Start with the compression gage at zero and crank the engine 3-5 seconds using the ignition key. 9. Return the ignition key to the OFF position. 10. Measure the compression for each cylinder. Record the readings. 11. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any 1 cylinder is 862 kPa (125 psi), the lowest allowable pressure for any other cylinder would be 607 kPa (88 psi). (862 kPa x 70% = 607 kPa) (125 psi x 70% = 88 psi). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. 12. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 13. Reinstall the Fuel Pump relay and Powertrain relay. 14. Using the scan tool, clear all diagnostic codes. Page 13052 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1812 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 14434 Steering Shaft: Service and Repair Steering Shaft Lower Bearing Replacement Steering Shaft Lower Bearing Replacement Page 10378 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9717 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Page 2933 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 14182 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 8215 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Clutch: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 1397 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 2746 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 2325 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 19790 procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Page 10482 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Page 6742 14. Install the PCV hose. 15. Gather the branches of the engine wiring harness and position over the top of the engine. 16. Position the engine wiring harness clip and install the clip bolt (4). Tighten the bolt to 9 Nm (80 lb in). Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 3896 8. Remove the connector position assurance (CPA) retainer (1). 9. Disconnect the engine harness electrical connector (2) from the ignition coil harness electrical connector. 10. Disconnect the engine harness electrical connectors (3) from the left side fuel injectors. 11. Remove the engine harness clip (4) from the ignition coil bracket stud. 12. Remove the CPA retainer (1). 13. Disconnect the engine harness electrical connector (2) from the ignition coil harness electrical connector. 14. Disconnect the engine harness electrical connector (3) from the throttle actuator. 15. Remove the engine harness clip (4) from the ignition coil bracket stud. 16. Disconnect the engine harness electrical connectors (5) from the right side fuel injectors. Page 13499 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10392 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7146 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 1204 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Page 2464 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Page 17573 Note When installing the regulator (2) align the gear to the motor drivegear before installing the screw. 3. Install the regulator (2) to the motor/module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the screw (1) to the motor/module. Tighten nuts to 5 Nm (44 lb in). Note When removing the tension from the cables, depress and hold spring on the regulator to remove tension from the cable before locking the pulley into the frame. Once the pulley has been locked, the spring can then be release. 5. Install the rear sliding window pulley (1). Page 12694 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.8L and 5.3L) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (6.0L and 6.2L) Page 6184 Crankshaft Position (CKP) Sensor (Diesel) Initial Inspection and Diagnostic Overview Drive/Propeller Shaft: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Propeller Shaft Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Propeller Shaft (See: Symptom Related Diagnostic Procedures/Symptoms - Propeller Shaft) in order to identify the correct procedure for diagnosing the system and where the procedure is located. Page 17745 Page 2928 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 1672 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 7137 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 1196 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 10824 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . Rear Brake Caliper Overhaul (JH6, JH7) Page 4954 Page 19556 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 11442 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Page 10733 12. Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination. 13. Disconnect the right rear brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 14. Disconnect the left rear brake pipe fitting (2). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 13482 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16468 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Body - Tailgate Handle/Latch Binds/Hard To Open Tailgate Release Handle: Customer Interest Body - Tailgate Handle/Latch Binds/Hard To Open TECHNICAL Bulletin No.: 09-08-66-009A Date: May 25, 2010 Subject: Intermittent Pickup Box Endgate Latch Binding, Hard to Open, Does Not Open (Re-Work Endgate Latch Rods) Models: 2009 Chevrolet Silverado 2009 GMC Sierra Supercede: This bulletin is being revised to remove the endgate latch handle re-work. Please discard Corporate Bulletin Number 09-08-66-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the endgate is binding, is hard to open or does not open at all. Applying excessive upward force to the endgate latch handle may allow the endgate to open as designed. Cause This condition may be caused by a fitment concern with the endgate latch rods in the endgate assembly. Correction Re-work the right endgate right latch rod to increase the handle travel. Follow the re-work procedure below. 1. Remove the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. 2. Remove the right endgate latch. Refer to Endgate Latch Replacement in SI. 3. Remove the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 4. Remove the foam (1) from the latch rod. 5. Measure the overall length of the rod. Note the measurement. The following steps will instruct how to reduce the overall length of the rod by 3-4 mm (0.118-0.157 in). Page 17632 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Page 10998 6. Select Automated Bleed 11. Press Start to begin the automated bleed procedure. Ensure the J-29532-A orJ 29532 has not yet been installed to the vehicle. The travel and pressure sensors are being calibrated and learned by the EBCM during this step. 12. Press Start to continue. Note Approximately 2.5-3.0 L (2.6-3.2 qt) of brake fluid will be used throughout this procedure. Ensure there is an adequate supply of brake fluid in the J-29532-A orJ 29532 . 13. Inspect the fluid level in the J-29532-A orJ 29532 . Clean the outside of the J-29532-A orJ 29532 and add GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container, as necessary. 14. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Note Do not pressurize the J-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. 15. Install the J 35589-A and the J-29532-A orJ 29532 to the vehicle. Note Ensure a MINIMUM of 200 kPa (30 psi) of pressure is MAINTAINED in the J-29532-A orJ 29532 throughout this procedure, except as instructed. 16. Set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). 17. Open the J-29532-A orJ 29532 fluid tank valve to allow pressurized brake fluid to enter the brake system. 18. Wait approximately 30 seconds, then inspect the entire hydraulic brake system to ensure there are no existing external brake fluid leaks. 19. Secure bleeder hoses to all 4 brake caliper bleeder valves. 20. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 21. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 22. Press Start to begin the system automated bleed steps. Follow all instructions on the scan tool. Only apply the brake pedal when instructed to do so by the scan tool. 23. When instructed, firmly apply and release the brake pedal using smooth, consistent full brake pedal strokes. The brake pedal will go fully to the floor with some pedal feedback felt. The master cylinder reservoir supply circuit is being flushed through these steps. 24. Continue the brake applications until instructed by the scan tool. The scan tool will instruct to perform 10 brake applies. 25. When instructed by the scan tool, stop performing the brake applications and press Enter. The scan tool will instruct to perform Steps 23-25 2 more times. 26. When instructed by the scan tool, press Start to continue. Note The hydraulic brake system will be under high pressure during the next bleed sequence. Ensure the bleeder hose is maintained securely to the bleeder valve, and open the bleeder valve slowly. 27. Following the instructions on the scan tool, open the left rear (LR) brake caliper bleeder valve. 28. With the bleeder valve open and the bleeder hose maintained firmly in place, press Start to begin the bleeding process. This process will run in a 30-second cycle. The pump and HPA circuits are being flushed during these steps. 29. Press Enter when instructed to repeat the bleeding process 5 more times on the scan tool. 30. Press Enter when instructed at the end of the 6th bleeding process. 31. Ensure the LR brake caliper bleeder valve is tightened securely. 32. Reduce the charge in the air tank of the J-29532-A orJ 29532 to 0 kPa (0 psi). 33. Press Start to continue. The brake pedal simulator circuit is being flushed through this step. 34. Place shop cloths beneath the master cylinder brake pipe connections to protect the vehicle from the brake fluid expelled during the next sequence. 35. When instructed by the scan tool, set the pressure regulator of the J-29532-A or charge the air tank of the J 29532 to 200 kPa (30 psi). Page 12110 Junction Block - Left I/P X5 (SPO Alarm) Page 14943 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Top of the Headliner Components (Regular Cab) Page 8064 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 13130 Fuse Block - Auxiliary (HP2), Top View Page 6248 Manifold Absolute Pressure (MAP) Sensor (Gas Except 4.3L) Page 11361 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 16383 Page 18593 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 7635 Disclaimer Page 12668 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 20221 Hazard Flasher Relay: Diagrams Component Connector End Views Emergency Vehicle Roof Lamp Relay (5Y0) Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Page 15411 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Rear of the Engine Compartment Components A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Clutch: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 6456 5. Position and install the evaporative canister vent solenoid (1) to the vehicle. 6. Use 5/8 in heater hose (2) to secure both ends with hose clamps (3). Page 494 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12736 X300 Chassis Harness to Engine Harness (4.8L/5.3L/6.0L/6.2L) Page 7782 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 8278 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 12399 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19408 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13880 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 15536 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 16914 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 4681 6. Install the sight shield circuit breaker (2) and secure with bolts (1). Tighten the bolts to 5 Nm (44 lb in) . 7. Connect the APM assembly connectors (1 and 3) and install any removed locking tabs. 8. Connect the APM assembly connector (2) using the following procedure: 1. Push the lever up. Note Install the connector (2) without disturbing the position of the lever. DO NOT use the lever to install the connector in place. 2. Install the connector (2) onto the terminals by pushing on the connector only. 3. Rotate the lever after the terminals are engaged. 4. Push the green tab to lock the lever. Page 12164 Page 20555 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 9007 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 4527 Drive Motor Generator Battery Control Module X5 (HP2) Page 11932 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 15002 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 3412 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17225 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 9289 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Page 960 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 13517 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 5416 Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 2074 Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Service and Repair Axle Shaft: Service and Repair Rear Axle Shaft Replacement Special Tools * J 2619-01 - Slide Hammer W/1/2 x 13 Adapter * J 45859 - Axle Shaft Remover/Installer Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor. * For Hybrid vehicles, refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . * For non Hybrid vehicles (1500 series), refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . * For non Hybrid vehicles (2500 series), refer toRear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement) . 4. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement) . 5. Remove the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 6. Remove the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) )Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 7. Remove the and discard differential pinion gear shaft bolt. Note For those vehicles NOT equipped with the locking differential proceed to step 8. If the vehicle is equipped WITH the locking differential, proceed to step 9 and 10. Page 8191 Harness Components Page 3372 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 3640 17. Loosen the valve rocker arm cover bolts. 18. Remove the valve rocker arm cover. 19. Remove and discard the old gasket (1). 20. Remove the oil fill cap (424) from the oil fill tube (423), if necessary. 21. Remove and discard the oil fill tube, if necessary. Installation Procedure Page 14355 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 4703 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) Page 7940 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 16892 Page 20836 Page 12456 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 12604 X110 Inline Harness Connector End Views X110 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH) Page 14705 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 6287 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 4. Remove the HO2S (3). Installation Procedure Page 12480 Page 6491 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (2). 16. Remove the fuel/EVAP line clip nut (1). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Page 2889 Switch Position Icons Hybrid Controls Electronic Component Views Voltage Inverter Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 18858 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 8168 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 13430 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 19535 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2284 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 18639 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 10002 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 19406 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 7045 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 1301 Rear Side Door Outside Handle Replacement (Crew Cab) Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Crew Cab) Rear Side Door Outside Handle Replacement (Crew Cab) Page 12095 Page 5724 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16850 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 2373 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 15230 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 726 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Seals and Gaskets: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 6667 16. Position the engine wiring harness clip to the generator bracket and install the clip bolt (4). Tighten the bolt to 9 Nm (80 lb in). 17. Position and install the heater hose bracket (1) to the ignition coil bracket stud. Hoses shown removed for clarity. 18. Install the heater hose bracket nut (2). Tighten the nut to 9 Nm (80 lb in). Page 15582 1 - Window Switch -Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) -Right Rear (ASF) 3 - Door Latch -Right Rear 4 - Speaker -Right Rear 5 - Window Motor -Right Rear (A31) Driver Door Components (AN3/DL3) Page 7072 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Locations Steering Control Module: Locations Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 6781 9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. Page 6955 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 13224 Junction Block - Left I/P X3 (except MEX) Page 20910 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Left Rear of the Engine Compartment Components Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (4.3L) Page 14897 Air Door Actuator / Motor: Service and Repair Mode Valve Actuator Replacement Mode Valve Actuator Replacement Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 12188 Page 2676 Page 16713 Speaker: Service and Repair Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Page 15498 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 11150 9. Position the master cylinder (1) to the master cylinder adapter. 10. Install 2 new master cylinder nuts (1) and tighten to 33 Nm (24 lb ft) . 11. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . 12. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) . 13. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during this procedure. 14. Turn the ignition ON with the engine OFF. 15. Using the scan tool, perform the following steps: Page 15109 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 15749 Seat Belt: Service and Repair Seat Belt Latch Stop Installation Seat Belt Latch Stop Installation Page 13898 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 15612 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 16781 Disclaimer Page 6039 Engine Control Module (ECM) X1 (HP2) Page 13980 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 9313 27 - Differential Pinion Thrust Washer 28 - Differential Pinion Gear 29 - Differential Side Gear Washer 30 - Differential Side Gear 31 - Output Shaft Snap Ring 32 - Differential Pinion Gear 33 - Differential Pinion Gear Thrust Washer 34 - Differential Side Gear 35 - Differential Side Gear Washer 36 - Differential Cross Pin 37 - Ring Gear Bolt 38 - Output Shaft Bearing Assembly 39 8-Point Lock Ring 40 - Sleeve and Insert Assembly 41 - Differential Side Bearing Assembly 42 Carrier Gasket 43 - Carrier Cover 44 - Tube Locator Pin 45 - Inner Output Shaft Thrust Washer 46 - Inner Output Shaft Bearing Assembly 47 - Inner Output Shaft 48 - Carrier Bolt 49 - Shifter Spring 50 - Shifter Fork 51 - Shifter Fork Rod 52 - Tube Bolt 53 - Shift Actuator Assembly 54 - Output Shaft Seal Assembly 55 - Output Shaft Bearing Assembly 56 - Tube 57 - Tube Gasket 58 - Output Shaft Locator Thrust Washer 59 - Output Shaft Thrust Washer 60 - Output Shaft Snap Ring 61 Shifter Sleeve Page 7998 26 - Front Differential Case 27 - Differential Pinion Gear Shaft Lock Bolt 28 - Differential Side Bearing 29 - Differential Side Bearing Cup 30 - Front Differential Ring Gear 31 - Front Differential Half Carrier Location Pin 32 - Front Differential Bearing Adjuster Nut Lock 33 - Differential Pinion Gear 34 - Differential Pinion Gear Thrust Washer 35 - Differential Side Gear Thrust Washer 36 Differential Side Gear 37 - Differential Pinion Gear 38 - Differential Pinion Gear Thrust Washer 39 Front Differential Side Gear Spacer 40 - Front Differential Side Gear 41 - Front Differential Side Gear Thrust Washer 42 - Front Differential Drive Pinion Gear 43 - Differential Drive Pinion Gear Bearing Shim 44 - Front Differential Drive Pinion Gear Inner Bearing 45 - Front Differential Drive Pinion Gear Inner Bearing Cup 46 - Front Differential Drive Pinion Gear Bearing Spacer 47 - Front Differential Carrier Bushing 48 - Front Differential Carrier 49 - Front Differential Bearing Adjuster Nut Lock 50 - Bolt 51 - Front Differential Drive Pinion Gear Yoke Nut 52 - Front Differential Drive Pinion Gear Thrust Washer 53 - Front Differential Drive Pinion Gear Yoke 54 - Front Differential Drive Pinion Gear Bearing Dirt Deflector 55 - Front Differential Drive Pinion Gear Seal 56 - Front Differential Drive Pinion Gear Outer Bearing Cup 57 - Front Differential Drive Pinion Gear Outer Bearing 58 - Front Differential Carrier Bushing 59 - Differential Bearing 60 - Front Differential Bearing Adjuster O-Ring Seal 61 - Front Differential Bearing Adjuster 62 - Front Drive Axle Inner Shaft Seal 63 - Front Drive Axle Inner Shaft Retaining Ring 64 - Front Drive Axle Inner Shaft 65 Front Differential Carrier Vent 66 - Fuel and Oil Resistant Hose 67 - Clamp 68 - Front Differential Carrier Vent Hose Connector 69 - Front Differential Carrier Oil Drain Plug 70 - Front Differential Carrier Oil Drain Plug Washer 71 - Front Differential Carrier Oil Fill Plug 72 - Front Differential Carrier Oil Fill Plug Washer Page 8829 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8170 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 19542 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13009 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 10944 6. Install the remainingJ-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J-39544-KIT - Torque-Limiting Socket Set , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED * The rotor has NOT been refinished * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level 10. Mount a dial indicator,J-45101 - Hub and Wheel Runout Gage , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specifications: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. Page 9610 20. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer (2) and lightly tap each of the yokes (1) to seat the universal bearing against the retaining ring. Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12743 Page 18718 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 19969 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 2574 36. Press Start to begin the next bleed sequence. The brake modulator to master cylinder, or intermediate, brake circuits are being port bled during this sequence. Ensure each of the 2 intermediate brake pipe ports (1) is fully bled and securely tightened before the 60-second cycle is completed. 37. Loosen, but do not disconnect, one of the 2 intermediate brake pipe fittings (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 38. Tighten the first brake pipe fitting, then loosen, but do not disconnect, the second intermediate brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 39. Tighten the second intermediate brake pipe fitting. 40. If both of the intermediate brake pipe ports (1) were not fully bled within the 60-second cycle time, press Start to repeat Steps 37-39. 41. Press Enter to continue. The brake master cylinder to brake modulator, or primary, brake circuit is being port bled during this sequence. Ensure the primary brake pipe port (1) is fully bled and securely tightened before the 60-second cycle is completed. 42. Loosen, but do not disconnect, the primary brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 43. Tighten the primary brake pipe fitting (1). Page 12338 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8996 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 1675 Page 17819 Front Floor Panel Carpet Replacement (Extended Cab) Front Floor Panel Carpet Replacement (Extended Cab) Page 1404 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Page 10304 Control Solenoid Valve Assembly X3 (MYC/MYD) 1-2 Shift Solenoid (SS) Valve (M30) Page 13431 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Specifications Oil Pan: Specifications Oil Pan Baffle Bolts............................................................................................................................... ..........................................................9 Nm (80 lb in) Oil Pan Closeout Cover Bolt - Left Side............. .............................................................................................................................................9 Nm (80 lb in) Oil Pan Closeout Cover Bolt - Right Side.................................................................................... ....................................................................9 Nm (80 lb in) Oil Pan Cover Bolts.................................. ........................................................................................................................................................9 Nm (80 lb in) Oil Pan Drain Plug.......................................................................................................... ................................................................................25 Nm (18 lb ft) Oil Pan M6 Bolts - Oil Pan-to-Rear Housing............................................................................................................................ ...................12 Nm (106 lb in) Oil Pan M8 Bolts - Oil Pan-to-Engine Block and Oil Pan-to-Front Cover.....................................................................................................25 Nm (18 lb ft) Camshaft Position Actuator Magnet Replacement Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Magnet Replacement Camshaft Position Actuator Magnet Replacement Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement. 2. Disconnect the engine harness electrical connector from the camshaft position (CMP) actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note The gasket surface should be free of oil or other foreign material during assembly. Page 11634 Page 8558 Parking Pawl: Service and Repair Park Pawl and Actuator Replacement Park Pawl and Actuator Replacement Page 1124 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 9715 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 15708 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab with 10 Series with ASF) Page 13206 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 12108 Junction Block - Left I/P X3 (except MEX) OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: Customer Interest OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 2877 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Right Side of the I/P Components Page 10344 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 7943 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 11643 Page 4434 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 4196 Page 13708 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Page 20430 Switches and Relays Page 11284 3. Position the park brake pedal assembly on the side panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install and finger tighten the mounting nuts. Tighten the nuts to 25 Nm (18 lb ft) . 5. Connect the park brake warning lamp connection. 6. Install the park brake release handle to the instrument panel. 7. Install the park brake release handle bolt and tighten to 9 Nm (80 lb in) . 8. Install the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 9. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 10. Raise the vehicle. Page 20527 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 19842 Frequently Asked Questions Disclaimer Page 776 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 7138 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12241 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 19427 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13696 Multiple Junction Connector: Connector Locations Harness Routing Views Driver Door Harness Routing 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Passenger Door Harness Routing Page 10217 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16891 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 18710 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 16971 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Locations Steering Control Module: Locations Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 4154 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 3430 camshaft lobe, the valve spring force is reduced, allowing the locking pins to move, deactivating the intake valve. However, when cylinder deactivation is commanded ON, the exhaust valve for the deactivated cylinder is in the closed position, allowing the locking pins on the valve lifter to move immediately, and deactivate the exhaust valve. By deactivating the exhaust valve first, this allows the capture of a burnt air/fuel charge or exhaust gas charge in the combustion chamber. The capture of exhaust gases in the combustion chamber will contribute to a reduction in oil consumption, noise and vibration levels, and exhaust emissions when operating in V4 mode cylinder deactivation mode. During the transition from V8 to V4 mode, the fuel injectors will be turned OFF on the deactivated cylinders. To help prevent spark plug fouling, the ignition system secondary voltage or spark is still present across the spark plug electrodes on the deactivated cylinders. If all enabling conditions are met and maintained for cylinder deactivation operation, the ECM calibrations will limit cylinder deactivation to a cycle time of 10 minutes in V4 mode, then return to V8 mode for 1 minute. Switching between V8 and V4 modes is accomplished in less than 250 milliseconds, making the transitions seamless and transparent to the vehicle operator. The 250 milliseconds includes the time for the ECM to sequence the transitions, the response time for the VLOM solenoids to energize, and the time for the valve lifters to deactivate, all within 2 revolutions of the engine crankshaft. Valve Lifter Oil Manifold (VLOM) Assembly The cylinder deactivation system uses an electro-hydraulic actuator device called the valve lifter oil manifold (VLOM) assembly. The VLOM is bolted to the top of the engine valley, below the intake manifold assembly. The VLOM consists of 4 electrically operated normally closed solenoids. Each solenoid controls the application of engine oil pressure to the intake and exhaust valve lifters on the cylinders selected to deactivate. Engine oil pressure is routed to the VLOM assembly from an internal oil passage on the rear of the cylinder block. All 4 VLOM solenoids are connected in parallel to a fused ignition 1 voltage circuit, supplied by the powertrain relay. The ground or control circuit for each solenoid is connected to a low side driver internal to the engine control module (ECM). When all enabling conditions are met for cylinder deactivation, the ECM will ground each solenoid control circuit in firing order sequence, allowing current to flow through the solenoid windings. With the coil windings energized, the solenoid valve opens, redirecting engine oil pressure through the VLOM into 8 separate vertical passages in the engine lifter valley. The 8 vertical passages, 2 per cylinder, are connected to the valve lifter bores of the cylinders to be deactivated. When vehicle operating conditions require a return to V8 mode, the ECM will turn OFF the control circuit for the solenoids, allowing the solenoid valves to close. With the solenoid valves closed, engine oil pressure in the control ports is exhausted through the body of the solenoids into the engine block lifter valley. The housing of the VLOM incorporates several bleeds in the oil passages to purge any air trapped in the VLOM or engine block. To help control contamination to the hydraulic circuits, a small replaceable oil screen is located in the VLOM oil inlet passage, below the oil pressure sensor. The oil pressure sensor is a 3-wire sensor which provides oil pressure information to the ECM. During service, use extreme care in keeping the VLOM assembly free of any contamination or foreign material. Cylinder deactivation may be inhibited for many reasons, including the following: * Engine coolant temperature out of range for cylinder activation * Engine vacuum out of range * Brake booster vacuum out of range * Transmission gear incorrect or shift in progress * Accelerator pedal out of range or rate of pedal application too fast * Engine oil pressure and temperature out of range * Engine speed out of range * Vehicle speed out of range * Minimum time in V8 mode not met * Maximum V4 mode time exceeded * Decel fuel cutoff active * Reduced engine power active * Torque management active * Catalytic converter over temperature protection active * Piston protection active, knock detected * Cylinder deactivation solenoid driver circuit faults Page 10779 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral and Longitudinal Accelerometer Replacement Page 13756 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 6516 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 2545 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6730 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 14497 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 8670 Disclaimer Page 10206 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 13030 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11276 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. 5. Install the park brake cable to the cable guides. 6. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 7. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 8. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling) . 9. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Page 13174 Fuse Block - Auxiliary (HP2), Bottom View Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 269 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 15542 Air Bag Control Module: Connector Locations Harness Routing Views Body Harness Routing (Crew Cab except HP2) 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 Engine Splash Shield Replacement - Left Side Splash Guard: Service and Repair Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side Page 5486 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 11294 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JH6, JH7) Parking Brake Shoe Replacement (JH6, JH7) Page 14992 Blower Motor Control Module X2 Page 8265 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 6991 Ignition Coil 7 (4.8L/5.3L/6.0L/6.2L) Page 12068 Page 18592 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 2865 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) Chassis Harness Routing (Except LY6/LMM/HP2) Page 3922 23. Install the intake manifold (500). Note The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 24. Tighten the intake manifold bolts (512) until snug. 25. Tighten the intake manifold bolts to specifications. * Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in) . * Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in) . Page 7328 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 2635 Page 7876 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 2686 Fuse Block - Underhood X3 Page 8104 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2512 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities andFluid and Lubricant Recommendations . 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) in General Information. Page 9194 Page 19057 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 3909 See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 44. Perform the High Voltage Service connect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 20242 Page 1474 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Low Pressure Sensor (HP2) A/C Low Pressure Switch Page 12986 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 4599 Page 20535 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 20262 Page 3095 Fuse Block - I/P X4 Page 12464 Page 2890 Module Circuit Function Icons Page 12390 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 11838 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 1766 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 1350 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Front Frame and Underbody Components - 1 of 2 Page 8200 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 3132 Customer TPMS Information Page 18922 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Page 20686 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 4801 Page 757 4. Disengage the bracket retainer tabs (1) securing the ECM to the bracket. 5. Remove the ECM (3) from the bracket. Installation Procedure 1. Set the bottom of ECM into the ECM bracket tab (2). 2. Push the ECM (3) in securing the ECM to the bracket. Page 5647 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 18416 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Page 18848 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 6052 Page 12681 Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 18070 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Diagrams Oil Level Sensor: Diagrams Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Locations Fuel Pressure Sensor/Switch: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 8180 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC/MYD/M99) Control Solenoid Valve Assembly X2 (MYC/MYD) Page 17546 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Page 8835 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 13451 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 6245 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 8292 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid ............................................................................................................................. .................................................. 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 13283 Fuse Block - Underhood X6 Page 13441 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 20824 Page 7756 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 5775 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 15739 When in the correct location, the latch plate tongue will be between the webbing and the seat. U.S. dealers: For additional information, search gmtraining.com's Web Video Library for the May 2007 Emerging Issues video (course #10207.05D). Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13904 Page 13341 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Page 14337 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 14629 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 19630 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 12071 A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 11883 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 12956 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 18823 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1834 4. Install the CPA retainer (3). 5. Install the HO2S clip to the engine wiring harness clip (4). 6. Lower the vehicle. Page 7182 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Body - Tailgate Handle/Latch Binds/Hard To Open Tailgate Latch: All Technical Service Bulletins Body - Tailgate Handle/Latch Binds/Hard To Open TECHNICAL Bulletin No.: 09-08-66-009A Date: May 25, 2010 Subject: Intermittent Pickup Box Endgate Latch Binding, Hard to Open, Does Not Open (Re-Work Endgate Latch Rods) Models: 2009 Chevrolet Silverado 2009 GMC Sierra Supercede: This bulletin is being revised to remove the endgate latch handle re-work. Please discard Corporate Bulletin Number 09-08-66-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the endgate is binding, is hard to open or does not open at all. Applying excessive upward force to the endgate latch handle may allow the endgate to open as designed. Cause This condition may be caused by a fitment concern with the endgate latch rods in the endgate assembly. Correction Re-work the right endgate right latch rod to increase the handle travel. Follow the re-work procedure below. 1. Remove the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. 2. Remove the right endgate latch. Refer to Endgate Latch Replacement in SI. 3. Remove the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 4. Remove the foam (1) from the latch rod. 5. Measure the overall length of the rod. Note the measurement. The following steps will instruct how to reduce the overall length of the rod by 3-4 mm (0.118-0.157 in). Page 5237 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 14987 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 7812 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 20166 Roof Marker Lamp - Left (U01) Roof Marker Lamp - Middle (U01) Page 13157 Page 7286 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 6341 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Page 4232 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10252 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12166 Page 1908 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 3220 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 15282 Page 10219 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 20479 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 2685 Page 19645 Cigarette Lighter: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. TheJ 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. TheJ 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. IfJ 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 13476 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 10887 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Page 3281 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 1265 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 6635 Fuel Injector 2 (4.3L) Fuel Injector 2 (4.8L/5.3L/6.0L/6.2L) Page 12711 X176 Inline Harness Connector End Views Locations Battery Temperature Sensor/Switch: Locations Generator Battery Temperature Sensor Location Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 19377 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12361 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 9921 24 - Transfer Case Oil Fill Plug 25 - Transfer Case Oil Drain Plug 26 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 27 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 28 - Transfer Case Shift Detent Plunger Plug 29 - Transfer Case Shift Detent Plunger Plug - O-Ring - Seal 30 - Transfer Case Shift Detent Spring 31 - Transfer Case Shift Detent Plunger Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 - Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Insert 12 - Transfer Case Shift Fork Spring Page 7990 Page 10838 If the Front Pad Kit listed is used to correct any condition other than the condition described in this bulletin, the vehicle could experience higher mileage corrosion-induced brake pulsation. If the condition described HAS NOT been verified, or if the condition observed IS NOT most noticeable through the steering wheel, the observed condition may have a different cause, such as a tire/wheel or rear brake issue, etc. Refer to SI for any further related diagnostics. If the condition described has been verified, and if the condition is most noticeable through the steering wheel, and if the condition was eliminated after driving the vehicle on relatively flat ground, typically for 1.5-3‹›km (1-2 mi), perform the following inspections and repairs. Important - It is critical to use the proper OEM brake rotors. Use of Non-OEM rotors may prevent the condition from being corrected long term. - If Non-OEM rotors are identified, these rotors are NOT covered under the GM New Vehicle Limited Warranty. 1. Inspect the front brake rotors to ensure that they are OEM rotors. - Remove the brake rotor from the vehicle. - Inspect the back side of the rotor for the Bosch Logo. If the Bosch logo IS NOT present, replace with OEM GM rotors, P/N 25819670. 2. Inspect the front brake rotors for Assembled Lateral Runout (LRO) and thickness variation. Follow SI procedures. 3. Inspect the front brake rotors for minimum thickness. Follow SI procedures. 4. If the rotors are within specifications, DO NOT refinish or replace the rotors. 5. If the rotors are out of specifications, refinish the rotors on a qualified lathe, or replace the rotors as appropriate. Follow SI procedures. Note To prevent a noise concern, follow the brake pad insulator preparation and seating instructions as referenced in Front Brake Pad Replacement (1500) in SI. 6. Install the specified front pad kit, GM P/N 25910432. Follow SI procedures. 7. Ensure that the condition has been eliminated under the same conditions. Parts Information Warranty Information Page 12584 1 - Door Frame 2 - X800 Right Rear Door Harness Routing (Crew Cab) Page 2639 Fuse Block - Underhood X1 Page 13568 Junction Block - Right I/P X2 Page 9513 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Page 11938 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 11353 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 5117 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (4.3L) Manifold Absolute Pressure (MAP) Sensor (Diesel) Page 19581 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 6489 Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 18799 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4740 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Under the Front Seats Components Page 1916 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 11099 15. Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting. 16. Connect the EBCM electrical connector. 17. Connect the electronic brake control position sensor electrical connector. 18. Tighten the brake modulator manual pressure relief valve (1) to 40 Nm (30 lb ft) . Page 11122 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . 6. Install the ABS module splash shield retainer (1). 7. Lower the vehicle. Page 13469 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 18663 Seat Cushion: Service and Repair Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Page 18927 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Page 13606 Page 13348 Junction Block - Left I/P X4 (except MEX) Page 8869 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 17692 Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Removal Procedure Note Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Page 13790 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 3383 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 6125 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 18818 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 7915 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2253 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 13909 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse Block/Diagrams/Connector Views) to locate the electrical center where the relay exists. Note * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 12452 Junction Block - Right I/P X2 Page 17462 For vehicles repaired under warranty, use the table above. Disclaimer Page 6922 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Powertrain Component Views Left Side of the Engine Components (Diesel) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 3763 Inspect closely for the temporary steel sealing device (1) being positioned tightly to the gasket (2) as shown. Only a small corner (1) of the temporary steel sealing device may be observable, depending on orientation. Perform a visual inspection in order to verify that the oil leak is coming from the engine oil cooler hose/pipe adapter area or the gasket where it connects to the engine. ‹› If the leak is coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, proceed to Step 4. ‹› If the leak is not coming from the engine oil cooler hose/pipe adapter area, the bolts or the gasket where it connects to the engine, refer to Oil Leak Diagnosis in SI. 4. To gain clearance, loosen or remove the engine oil cooler hose/pipe retaining bracket bolt (1). 5. Remove the engine oil cooler hose/pipe adapter bolts (2). 6. Remove and DISCARD both the temporary steel sealing device if present and the gasket. 7. Clean the mating surfaces of the engine oil cooler hose/pipe adapter and the engine. 8. Clean both bolt holes with brake cleaner and dry using regulated compressed air. 9. Clean both bolt threads and apply Pipe Sealant P/N 12346004 (Canada P/N 10953480) or equivalent (Loctite(R) 565) to the bolt threads. Verify that the sealant is applied 360 degrees around the bolt and extends from the tip of the bolt and covers at least 15 mm (0.59 in) of threads. 10. Install the engine oil cooler hose/pipe adapter with a NEW gasket. Page 9147 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 1745 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 4692 3. Remove the temporary coolant pipe caps (1). Caution: The module must be drained of all residual coolant prior to disassembly. Failure to properly drain all residual coolant may cause electronic circuit damage to occur during disassembly. Note Place a container under the coolant outlet pipe to capture the escaping coolant. 4. Drain the drive motor generator control module assembly of residual coolant by applying 30 psi regulated compressed air to the coolant inlet pipe until no coolant remains. 5. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 6. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit Page 19242 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Page 13443 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 685 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 14976 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 16878 Disclaimer Page 2556 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Sunroof Window Replacement (Crew Cab) Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Crew Cab) Sunroof Window Replacement (Crew Cab) Removal Procedure Note The sunroof must be in the fully closed position prior to removing the sunroof window. 1. Open the sunshade panel. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. Installation Procedure 1. Position the sunroof window (1) to the vehicle. 2. Loosely insert the screws (2) that retain the sunroof window (1) to the sunroof module assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments )Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments) . Tighten the screws to 3 Nm (27 lb in). Page 3211 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair) . Page 2989 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Page 15548 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab without 10 Series) Page 6925 Right Side of the Engine Components (Diesel) 1 - Fuel Injector 7 2 - Fuel Injector 5 3 - Fuel Injector 3 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Fuel Injector 1 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 7 - Intake Air Valve 8 - Crankshaft Position (CKP) Sensor 9 - Glow Plug 1 10 - G103 11 - G105 12 - Block Heater 13 - Glow Plug 3 14 - Glow Plug 5 15 - Water In Fuel Sensor 16 - Starter Motor 17 - Glow Plug 7 Rear of the Engine Components (Diesel) Page 7653 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 2404 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations . 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Page 14914 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 15715 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 8773 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18258 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heatng and Cooling Module - Passenger (KB6) Page 996 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 9086 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 20453 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1269 Page 13040 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 13408 Page 20179 Page 19371 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 4361 Warranty Information For vehicles with Exhaust Pinging/Popping/Snapping Noise, NO repairs are necessary as it is a normal condition. For vehicles repaired for a muffler buzz, use the labor operation. Disclaimer Page 7212 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 718 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 19991 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12143 Fuse Block - I/P X3 Page 15097 HVAC Control Module X2 (CJ2) Page 10330 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Page 6176 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 7735 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 6028 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Rear of the Engine Compartment Components Page 18102 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 7234 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Page 10937 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * J-39544-KIT - Torque-Limiting Socket Set , or equivalent * J-45101-100 - Conical Brake Rotor Washers Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 1. Remove the J-45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remainingJ-45101-100 - washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. Page 2662 Fuse: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 9216 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4646 16. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 17. Clean the sealing surface of the PIM cover as necessary. 18. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 19. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . Page 8224 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 14797 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 11702 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 12266 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Page 6389 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 10370 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 16198 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 15369 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12185 Fuse Block - I/P X2 (except MEX) Page 15948 1 - Inflatable Restraint Roof Rail Module -Passenger (ASF) 2 - Data Link Resistor 2 (HP2) 3 - Seat Belt Pretensioner -Passenger Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Clamp: All Technical Service Bulletins Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Page 5797 High Speed Bus - 2 of 6 (except MEX/HP2) Page 17502 Page 2741 Junction Block - Rear Lamps X4 Page 10505 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 7170 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 2673 Page 18962 Door Lock/Window Switch - Driver X3 (AN3/DL3) Page 14558 7. Install the J 36202 on the adjustment arm and the support assembly. 8. Using the J 36202 , increase the tension on the adjustment arm in order to load the torsion bar. 9. Align the reference marks, turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the support assembly. 11. Remove the safety stand and lower the vehicle. 12. Measure the Z height . Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . Page 5765 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 5366 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 15020 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Page 5692 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 12686 X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (NQF/NQH/HP2 Except Late Production with 4.8L/5.3L/6.0L/6.2L) Page 17840 Roof Rear Console Replacement (with DVD) Roof Rear Console Replacement (with DVD) Page 12865 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 7135 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 16804 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 8063 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 436 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 1960 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Left Rear Door Components (Extended Cab) Page 18914 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 5463 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 15591 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 11214 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 3659 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 16716 Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Page 15601 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 10204 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 20167 Roof Marker Lamp - Right (U01) Page 17384 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Page 10708 Electronic Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 9874 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 4668 Page 12411 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 7738 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 5076 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Page 6766 19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 22. Remove the fuel line bracket bolt (1). 23. Remove the fuel/EVAP line clip nut (2). 24. Remove the fuel/EVAP line clips from the frame and crossmember. 25. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure 1. If equipped with 4WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1). Audio - Radio Does Not Mute Enough When Using OnStar(R) Communications Control Module: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 13470 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 13455 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 17136 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (Except MEX/EXP) Page 15200 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 13277 Fuse Block - Underhood X3 Page 10445 Page 12415 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 4971 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 3470 14. Remove the EN 46330 . 15. Tighten the CMP actuator solenoid valve. 1. Tighten the valve a first pass to 65 Nm (48 lb ft). 2. Tighten the valve a final pass to 90 degrees using J 45059 . Page 2185 Sliding Rear Window Close Relay (A48) Page 10912 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 17135 Trailer Connector: Connector Locations Harness Routing Views Camper Harness Routing and Chassis Harness Routing - Rear 1 - X414 (UY2/8S3) 2 - J420 (UY2) 3 - Camper/Trailer Harness 4 - J415 (UY2) 5 - Chassis Harness 6 - J416 (UY2) 7 - J417 (UY2) 8 - J414 (UY2) 9 - J421 (UY2) 10 - J410 (UY2) 11 - Blunt Cut - Camper Trailer Provision (UY2) 12 - G401 (except LY6/LMM) 13 - Trailer Connector (UY7) Page 8981 Component Parts Page 6519 Fuel System Diagnosis (w/FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) supplies voltage to the fuel pump control module (FPCM) when the ECM detects that the ignition is ON. The voltage from the ECM to the FPCM remains active for 2 seconds, unless the engine is in Crank or Run. While this voltage is being received, the FPCM closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank pump module in order to maintain the desired fuel rail pressure. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH-48027 Digital Pressure Gage * J 37287 Fuel Line Shut-off Adapter Circuit/System Verification Important: * Repair all fuel system related DTCs before performing this diagnostic, unless instructed here from a DTC diagnostic. * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. 1. Ignition OFF, all accessories OFF, install aCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. 3. Engine ON with the engine idling at normal operating temperature, the Fuel Rail Pressure Sensor parameter should read between 296.4 - 310.3 Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 4448 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 5863 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Page 7914 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 18485 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Page 7900 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 7340 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Electronic Traction Control Switch Replacement Page 1440 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2/C67) Page 1608 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 10956 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH6) Rear Brake Rotor Replacement (JH6) Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 4374 6. If vehicle has a crew cab, remove the exhaust heat shield nuts. 7. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Installation Procedure 1. If vehicle has a crew cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in) . A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 20984 Wiper Motor: Diagrams Component Connector End Views Windshield Wiper Motor Page 18789 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3024 Fuse Block: Connector Views Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 12014 Fuse Block - Auxiliary (HP2), Top View Page 15058 Page 4903 4. Disengage the bracket retainer tabs (1) securing the ECM to the bracket. 5. Remove the ECM (3) from the bracket. Installation Procedure 1. Set the bottom of ECM into the ECM bracket tab (2). 2. Push the ECM (3) in securing the ECM to the bracket. Page 10454 27 - Differential Pinion Thrust Washer 28 - Differential Pinion Gear 29 - Differential Side Gear Washer 30 - Differential Side Gear 31 - Output Shaft Snap Ring 32 - Differential Pinion Gear 33 - Differential Pinion Gear Thrust Washer 34 - Differential Side Gear 35 - Differential Side Gear Washer 36 - Differential Cross Pin 37 - Ring Gear Bolt 38 - Output Shaft Bearing Assembly 39 8-Point Lock Ring 40 - Sleeve and Insert Assembly 41 - Differential Side Bearing Assembly 42 Carrier Gasket 43 - Carrier Cover 44 - Tube Locator Pin 45 - Inner Output Shaft Thrust Washer 46 - Inner Output Shaft Bearing Assembly 47 - Inner Output Shaft 48 - Carrier Bolt 49 - Shifter Spring 50 - Shifter Fork 51 - Shifter Fork Rod 52 - Tube Bolt 53 - Shift Actuator Assembly 54 - Output Shaft Seal Assembly 55 - Output Shaft Bearing Assembly 56 - Tube 57 - Tube Gasket 58 - Output Shaft Locator Thrust Washer 59 - Output Shaft Thrust Washer 60 - Output Shaft Snap Ring 61 Shifter Sleeve Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 11072 Page 7125 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 19661 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 3537 2. Install the NEW rear housing gasket (1), rear housing with seal (2), rear housing-to-engine bolts (3) and oil pan-to-rear housing bolts (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Tighten the rear housing-to-engine bolts (3) until snug. Do not overtighten. Tighten the oil pan-to-rear housing bolts (4) to 12 Nm (106 lb in). 4. Tighten the rear housing-to-engine bolts (3). Tighten the bolts to 30 Nm (22 lb ft). 5. Remove the J 41479-2A . 6. Install the automatic transmission flexplate. Refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair) . Installation Procedure - Cover without Seal 1. Position a NEW rear oil seal housing gasket (3) and the housing (2) to the engine. Page 12286 Page 9406 14. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 15. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. 16. Remove the oil seal using a suitable seal removal tool. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution) . 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 3567 4. Remove the crankshaft balancer bolt (139). Do not discard the crankshaft balancer bolt at this time. The old balancer bolt will be used during the balancer installation procedure. 5. Install the J 41816-A (1) and J 41816-2 (2) to the crankshaft balancer. Page 8868 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 10369 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 3071 Page 12770 X800 Right Rear Door Harness to Body Harness (Extended Cab) Page 20483 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18007 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 18062 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 15425 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 14461 Ball Joint: Specifications Ball Joint Inspection (Lower Ball Joint) .............................................................................................................................. No More Than 2 mm (0.079 in) Ball Joint Inspection (Upper Ball Joint) .............................................................................................................................. No More Than 2 mm (0.079 in) Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 5069 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 3951 8. Remove the oil level sensor from the oil pan. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the oil level sensor to the oil pan. Tighten the sensor to 20 Nm (15 lb ft). 2. Connect the engine harness electrical connector (1) to the oil level sensor. Page 4662 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 5982 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 18061 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Page 12076 Page 4627 Accessory DC Power Control Module (APM) Location The APM is affixed to and located underneath the PIM. It is fastened to the PIM with external mounting fasteners and 2 internal high voltage circuit connection fasteners. The APM shares a coolant passage with the PIM and as such is gasketed to the PIM. Operating Functions The APM is the device which converts high voltage (300V) direct current (DC) to low voltage (12V) DC for accessory electrical operation and to charge the 12 volt accessory battery. The APM also converts HV DC to intermediate (42V) DC to supply the electric power steering system with voltage. The APM is capable of supplying up to 175 Amps of 12 volt DC and up to 50 Amps of 42 volt DC. In Jump Assist mode the APM converts 12 volt DC to HV DC to charge the high voltage hybrid batteries. The APM is capable of supplying up to 2.7 Amps at 290 volts DC on the high voltage circuit when operating in Jump Assist. An external 12V DC battery charger is required during the Jump Assist mode because the APM and vehicle controllers may draw as much as 80 Amps of current from the vehicles 12 volt DC system. Communication and Hosted Diagnostics The APM has internal diagnostic tests that run at both power-up and during operation. All DTCs from the APM are reported to and hosted by the HPCM. The APM communicates directly only with the HPCM and only on the high speed hybrid GMLAN communication circuit. Circuit Inputs Inputs supported by the APM include the high voltage and 12 volt circuits. The APM also monitors various internal components for current, voltage and temperature. The APM is also connected to the high speed hybrid GMLAN communication circuit. An individual 12 volt discrete circuit powers ON the APM. The APM will not begin conversion of voltage however, until the appropriate GMLAN enable signal is communicated to it by the HPCM. Circuit Outputs The only outputs supported by the APM are the 12 volt and 42 volt conversion during normal vehicle operation and high voltage conversion during Jump Assist. Page 4389 Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . Page 3962 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Intake Manifold/Service and Repair) . Page 7376 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 20457 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 9030 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 12011 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12482 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 14178 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 16941 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1421 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 6744 24. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector. 25. Install the CPA retainer (2). 26. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following: 1. Ensure that the CPA retainer is pulled out 1 click. 2. Connect the electrical connectors to their corresponding injectors. 3. Push the CPA retainer in 1 click. 4. Ensure that the connector is secured. 27. Install the engine wiring harness clip (4) to the ignition coil bracket stud. 28. Connect the engine wiring harness electrical connector (1) to the MAP sensor (4). 29. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid (3). Page 19465 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 13821 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) Page 16452 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 7036 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 6875 Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Page 4284 Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 5. Remove the spark plug wires (1) from the spark plugs. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 6. Remove the spark plug wires from the ignition coils. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the oil level indicator tube bolt (419). 8. Remove the oil level indicator tube (420) from the engine block. 9. Remove the exhaust manifold bolts and exhaust manifold. Page 5788 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 10537 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 4885 Engine Control Module (ECM) X2 (4.3L) Page 12462 Page 15956 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)) . 6. Cut the seat belt pretensioner harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connections is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. Page 4516 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 9383 necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems) . 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages () . Page 10888 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Page 14869 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 15236 A/C Refrigerant Pressure Sensor (Diesel) A/C Refrigerant Pressure Sensor (Gas Except HP2) Page 12369 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11887 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Page 13738 X175 Engine Harness to Transmission Internal Harness (M30) Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10187 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 13138 Page 20218 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Page 515 Audible Warning Device Control Module: Diagrams Component Connector End Views Chime Module (UL5) Page 11142 Brake Fluid Level Indicator Switch Replacement (JD9, JF3, JF7) Brake Master Cylinder Adapter Replacement Removal Procedure 1. Place the transmission in the PARK or NEUTRAL position. 2. Apply the park brake. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 3. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 20599 Sliding Rear Window Switch (A48) Window Switch - Driver X1 (A31 without AN3/DL3) Page 9510 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Page 17713 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 10223 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 15595 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (Except 10 Series) Page 3025 Fuse Block - Auxiliary (HP2), Top View Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 3749 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter (437) if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430). Tighten the drain plug to 25 Nm (18 lb ft). Page 15603 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Service and Repair Muffler: Service and Repair Exhaust Muffler Replacement (With 1500, V8 Engine or LU3) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Lower the spare tire. 3. Remove the catalytic converter to exhaust muffler nuts. 4. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 7. 5. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 6. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. Page 6603 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Page 20521 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 10423 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 2732 Junction Block - Right I/P X4 Page 11656 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 7524 Disclaimer Page 13744 Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 10268 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7571 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Page 19524 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 2745 Fuse Block - I/P Top View Page 1600 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 12514 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 15859 Disclaimer Page 10955 Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft) . Page 7941 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8763 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 13987 IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Disclaimer Page 5351 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 2283 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 4058 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 8217 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 9711 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 3279 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 10444 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 20509 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9719 Transmission Control Module (TCM) (MW7) Page 1048 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 6921 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 20440 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 12475 Fuse Block - Underhood X3 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 15475 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 20849 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Page 15376 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 15629 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 4993 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Endgate Linkage Replacement (Pickup Box) Tailgate Release Handle: Service and Repair Endgate Linkage Replacement (Pickup Box) Endgate Linkage Replacement (Pickup Box) Page 10820 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 2. Drain all the brake fluid from the caliper. Note The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 2628 Page 20638 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Right Rear Door Components (Extended Cab) Page 6959 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 8105 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10199 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 9803 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 12737 X300 Engine Harness to Chassis Harness (HP2) Page 10350 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 11658 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 13270 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 10092 Page 6356 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 13507 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 6034 Engine Control Module (ECM) X1 (Diesel) Page 4704 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 20536 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 12147 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 14069 Note Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Page 8817 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 13425 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Auxiliary Battery Negative Cable Replacement Negative: Service and Repair Auxiliary Battery Negative Cable Replacement Auxiliary Battery Negative Cable Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions) . 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . 2. Remove the auxiliary battery negative cable ground terminal bolt from the left cylinder head. 3. Remove the auxiliary battery negative cable from the vehicle. Installation Procedure Page 5900 4. Install the CPA retainer (3). 5. Install the HO2S clip to the engine wiring harness clip (4). 6. Lower the vehicle. Page 6853 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 5127 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 8165 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10947 5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded to the following specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in) 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JD9, JF3, JF7))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Front Disc Brake Pads Replacement (JH6, JH7)) and/orRear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Rear Disc Brake Pads Replacement (JH6, JH7)) . 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in) for each measurement. 4. Compare the lowest thickness measurement recorded to the following specifications: - Brake rotor minimum allowable thickness after refinishing 37.0 mm (1.457 in) - Brake rotor discard thickness 36.50 mm (1.437 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.10 in) - Brake rotor discard thickness 28.0 mm (1.10 in) - Brake rotor minimum allowable thickness after refinishing 18.5 mm (0.728 in) - Brake rotor discard thickness 18.0 mm (0.709 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) - Brake rotor discard thickness 27.50 mm (1.083 in) - Brake rotor minimum allowable thickness after refinishing 29.0 mm (1.142 in) Page 8900 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 3852 19. Install the oil pan drain plug (430). Tighten the drain plug to 25 Nm (18 lb ft). 20. Install the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement )Differential Carrier Assembly Replacement (2500 4WD) () . 21. Raise the steering rack in place and install the steering rack bolts. * Tighten the left side steering rack bolts to 200 Nm (148 lb ft). * Tighten the right side steering rack bolts to 100 Nm (74 lb ft). 22. For 2500 series vehicles, position the oil pan skid plate and tighten until snug the 2 rear oil pan skid plate bolts, install the 2 front oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). Page 16988 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 20554 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 8055 Page 14931 Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 13814 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 14302 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 9156 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 10280 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 18272 Page 2174 Power Window Switch: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 5128 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 20625 Rear Door Window Motor: Service and Repair Rear Sliding Window Module Replacement Rear Sliding Window Module Replacement Removal Procedure Note The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 14916 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 19604 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 13319 Page 9255 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Page 9493 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Locations Steering Mounted Controls Assembly: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 3509 CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft, through the 4X signal of the CMP sensor. If the difference between the actual and the desired position is greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Page 7703 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 12074 Fuse Block - Underhood Bottom View Page 727 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 6473 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 19365 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Page 1223 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 8218 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Page 20127 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Page 16379 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Page 10466 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD and SHD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Inserts 12 - Transfer Case Shift Fork Spring 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case High/Low Shift Fork 15 - Transfer Case High/Low Shift Fork Inserts 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case Shift Detent Lever Assembly 18 - Transfer Case Rear Output Shaft 19 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 20 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 21 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 22 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Outer Page 109 Page 12152 Page 19822 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Locations Steering Angle Sensor: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 16963 Disclaimer Page 9917 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Selector Switch - O-Ring - Seal 7 - Transfer Case Shift Control Switch Assembly 8 - Transfer Case Front Half 9 - Transfer Case Half Locating Pin 9 - Transfer Case Half Locating Pin 10 - Transfer Case Input Shaft Bearing Assembly 11 - Transfer Case Input Shaft Inner Retaining Ring 12 - Transfer Case High/Low Internal Gear 13 - Transfer Case High/Low Internal Gear Retaining Ring 14 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 15 - Vehicle Speed Sensor Assembly 16 - Vehicle Speed Sensor O-Ring - Seal 17 - Transfer Case Rear Half 18 - Transfer Case Access Hole Plug 19 - Transfer Case - Harness - Bracket 20 - Transfer Case Half Bolt/Screw (Qty: 17) 21 - Transfer Case Rear Output Shaft Bushing 22 - Transfer Case Rear Output Shaft Seal 23 - Transfer Case Oil Fill Plug 24 - Transfer Case Oil Drain Plug 25 - Transfer Case Front Output Shaft Rear Bearing Assembly 26 - Transfer Case Shift Detent Plunger Plug 27 - Transfer Case Shift Detent Plunger Plug O-Ring - Seal 28 - Transfer Case Shift Detent Spring 29 - Transfer Case Shift Detent Plunger 30 Transfer Case Shift Detent Lever Bearing Assembly 31 - Transfer Case Shift Lever Seal 32 Transfer Case Shift Lever 33 - Transfer Case Control Lever Bolt/Screw 34 - Transfer Case Shift Lever - Rubber - Seal Internal Components Page 14096 Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Page 12402 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 6987 Ignition Coil 3 (4.8L/5.3L/6.0L/6.2L) Page 17570 6. Remove the screw (1) from regulator (2). 7. Remove the regulator (2) from the motor/module. Note When removing the tension from the cables, depress and hold spring on the regulator to remove tension from the cable before releasing the pulley from the frame. Once the pulley has been released, the spring can then be released. 8. Remove the pulley (1) from the frame. 1. Lift the end of the tabs (2) out of the window frame (3). 2. Turn upward to release the pulley (1) from the frame (3). Page 9919 23 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Inner 24 - Transfer Case Front Output Shaft Drive Chain Assembly 25 - Transfer Case Front Output Shaft Drive Sprocket 26 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 27 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 28 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 29 - Transfer Case Oil Pump Assembly 30 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 31 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 32 Transfer Case Rear Output Shaft Rear Bearing Assembly 33 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 34 - Transfer Case Oil Pump Suction Pipe 35 - Transfer Case Oil Pump Suction Pipe Seal 36 - Transfer Case Front Output Shaft Driven Sprocket Spacer Spring 37 Transfer Case Front Output Shaft Driven Sprocket Spacer 38 - Transfer Case Front Output Shaft Driven Sprocket 39 - Transfer Case Front Output Shaft Hole Plug 40 - Transfer Case Front Output Shaft 41 - Transfer Case Front Output Shaft Front Bearing Assembly Page 14171 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 9350 Actuator: Diagrams Component Connector End Views Front Drive Axle Actuator (NQF/NQG/NQH) Page 6640 Fuel Injector 8 (4.8L/5.3L/6.0L/6.2L) Fuel Injector 8 (Diesel) Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Service and Repair Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement Special Tools J 43181 Heater Line QC Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Using the J 43181 disconnect the inlet heater hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 4. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 5. Remove the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Battery Replacement) . 6. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) () . 7. Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Service Positioning (with SLT) (See: Body and Page 444 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 9804 For vehicles repaired under warranty, use the table above. Disclaimer Page 6328 6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 7. Remove the EN 46330 . Page 9155 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 19361 Cruise Control: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 18880 Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Front Seat Heater Switch Replacement (See: Seat Heater Switch/Service and Repair/Front Seat Heater Switch Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning) for MSM and door lock/window switch replacement, programming, and setup Heated/Cooled Seats Inoperative-(Split For Indexing)-Part 1 Heated/Cooled Seats Inoperative Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The heat and cool seat functions for the driver and passenger seats are controlled by the climate control seat module (CCSM) that is located under the passenger seat cushion. When a driver or passenger heat or cool seat switch is pressed, a low reference signal is applied through the switch signal circuit to the door lock/window switch. In response to the switch input, the door lock/window switch simultaneously illuminates the appropriate heated/cooled switch indicators and sends a serial data message to the memory seat module (MSM) indicating the heat or cool seat request. The MSM then sends a pulse width modulation (PWM) signal through the appropriate heated/cooled seat mode signal circuit to the CCSM. The CCSM then applies battery positive voltage to the seat cushion and seat back thermal electronic devices (TEDs) and a pre-determined voltage to the blower motors. To determine seat temperature, the CCSM supplies a 5 V signal and a low reference to the temperature sensors that are attached to each TED. The temperature sensors Page 983 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 5373 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Fluid Pump: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20202 Page 8476 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 12235 Junction Block - Left I/P X8 (except MEX) Page 4909 Page 4150 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 14907 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Left Side Floor Air Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the push pin (5) from the left floor air outlet duct (4). 2. Remove the left floor duct (1) from the HVAC module (2). Installation Procedure 1. Install the left floor air outlet duct (1) to the HVAC module (2). 2. Install the push pin (2) to the left floor air outlet duct . Page 9972 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 6904 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 4677 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 9. Remove the HV dc electric air conditioning compressor module (ACCM) cable terminal fasteners (1). 10. Remove the HV dc electric ACCM cable mounting fasteners (3). 11. Remove the HV dc electric ACCM cable (4) from the PIM distribution box. 12. Remove the HV dc battery cable terminal fasteners (2). 13. Remove the HV dc battery cable mounting fasteners (5). 14. Remove the HV dc battery cable (6) from the PIM distribution box. 15. Inspect and retain the seals (7). 16. Remove the drive motor generator position sensor shield circuit fastener (2). 17. Remove the shield circuit harness (1). 18. Remove the PIM cooling inlet (4) and outlet (5) hoses. 19. Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle. Page 13325 Page 7843 Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 6834 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 2788 Fuse Block - I/P Top View Page 18734 Component Parts Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 5631 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 19515 Switches and Relays Page 4784 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 16257 Page 10564 Transmission Control Module (TCM) (MW7) Page 19071 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Page 468 Page 8356 For vehicles repaired under warranty, use the table. Disclaimer Page 1369 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Page 7229 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 465 Radiator Cooling Fan Motor Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 5010 Page 10347 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 6901 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 12220 Fuse Block - Mobile Radio (9L4) Page 4865 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement - Accessory Drive Belt Tensioner Replacement - Accessory Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory) . 2. Remove the drive belt tensioner bolts. 3. Remove the drive belt tensioner. Installation Procedure 1. Position the drive belt tensioner to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 2923 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 12311 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 3898 23. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. 24. Position the hose out of the way. 25. Loosen the intake manifold bolts (512). Note The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 26. Remove the intake manifold (500). 27. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages. Page 1290 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 3115 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 5745 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 8164 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 6518 * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 . 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Remove the J 37287 andCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal ). 5. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system components test normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Service and Repair )Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair) Fuel System Diagnosis (W/FPCM) Page 20071 Page 1305 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 3081 Fuse Block - Underhood X3 Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 19348 Switch Position Icons Page 6701 Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas Except 4.3L/LY6) Page 13144 Page 17071 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 2665 Fuse Block - Auxiliary X1 (HP2) Page 8060 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 9471 11. Push in on the rear axle shaft (2) and remove the lock (1). Note If the rear axle shaft is difficult to remove, proceed to step 14. 12. Remove the rear drum brake axle shaft (2) from the rear axle assembly (1), if equipped. Page 20381 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 10185 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 15310 Control Module HVAC: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 895 Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: Customer Interest Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 5057 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 18741 Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 14173 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 19656 Compass: Service and Repair Electronic Compass Module Replacement Page 15611 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Passenger Seat Components - 1 of 2 Page 1278 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 10387 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 6204 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 10331 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 10264 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 11650 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 20231 Page 4891 Page 7132 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Headlining Trim Panel Replacement (Crew Cab) Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab) Headlining Trim Panel Replacement (Crew Cab) Page 10902 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 10417 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 6817 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. If equipped with 5 ft 8 in. bed, perform the following steps: 11. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 12. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 13. Remove the fuel tank fill pipe. 14. Cap the opening on the fuel tank in order to prevent possible system contamination. Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8397 Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 12528 For vehicles repaired under warranty, use the table. Disclaimer Page 20783 6. Remove the screw (1) from regulator (2). 7. Remove the regulator (2) from the motor/module. Note When removing the tension from the cables, depress and hold spring on the regulator to remove tension from the cable before releasing the pulley from the frame. Once the pulley has been released, the spring can then be released. 8. Remove the pulley (1) from the frame. 1. Lift the end of the tabs (2) out of the window frame (3). 2. Turn upward to release the pulley (1) from the frame (3). Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 15878 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 13208 Fuse Block - I/P X2 (except MEX) Page 1483 Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 1329 Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Page 7374 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 8757 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 5841 Page 15381 1 - Electronic Compass Module (YE9) Top of the Headliner Components (Extended Cab) Page 2301 4. Brush or using compressed air, blow away any dirt from around the spark plug. 5. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Page 7654 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 12501 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . Page 17619 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Page 7220 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 486 Page 8072 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12728 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 10545 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Steering/Suspension - Ball Joint Availability Control Arm: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Page 694 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 3786 * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 15. Install the oil cooler lines to the radiator. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement) . Page 12100 The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Fuse 11 ................................................................................................................. ...................................................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 8103 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Locations Towing Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 10925 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Page 13378 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Engine Harness Routing - Left Side (4.3L) Page 9486 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models orJ-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models orJ-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note Alternate between the bolts until both sides of the top half of the tool touch the bottom half . 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. High Mount Stop Lamp Replacement (Extended and Crew Cab) Center Mounted Brake Lamp: Service and Repair High Mount Stop Lamp Replacement (Extended and Crew Cab) High Mount Stop Lamp Replacement (Extended and Crew Cab) Page 20878 11. Connect the large two-wire connector (1) to the body harness (2). 12. Connect the small five-wire connector (1) to the body harness (2). 13. Secure the large two-wire connector and small five-wire connector to the windshield washer solvent heater assembly bracket. 14. Connect the two windshield wiper solvent inlet and outlet hoses together. Use a portion of the rubber wiper solvent hose removed in Step 1 if needed to join the two plastic wiper solvent hoses together. Discard the remaining portions of the rubber windshield wiper solvent hoses. 15. Route and secure windshield wiper solvent hose along passenger side front fender. Page 14647 Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair) . Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 14955 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 12242 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Page 13180 Fuse Block - Mobile Radio (9L4) Page 10412 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19952 Page 18782 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Restraints - Air Bag Readiness Light On. Malfunction Lamp / Indicator: Customer Interest Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 3843 14. Remove the right side transmission cover bolt (2). 15. Remove the left side transmission cover bolt and cover. Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 5439 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 8131 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure Antilock Brake System Automated Bleed Procedure Special Tools * J 29532 Diaphragm Pressure Bleeder, orJ-29532-A Brake Pressure Bleeder, or equivalent * J 35589-A Brake Bleeder Adapter, or equivalent Warning At times during this brake bleed procedure brake fluid will be under higher pressures than during typical brake bleed procedures. Ensure the bleeder hose attached to the bleeder valve is securely maintained in position whenever the bleeder valve is opened. Failure to maintain the bleeder hose securely to the valve when opened, may allow the hose to blow off and brake fluid to spray out of the bleeder valve, possibly resulting in personal injury. Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note * Do not pressurize the brake pressure bleederJ-29532-A orJ 29532 and thereby the master cylinder reservoir until instructed to do so by the scan tool. Portions of the automated bleed process require the master cylinder reservoir not be pressurized through the J-29532-A orJ 29532 . * Do not apply the brake pedal until instructed to do so by the scan tool. Applying the brake pedal before instructed by the scan tool may result in setting a DTC and may require the sensor and boost valve calibration and electronic brake control module (EBCM) learn procedures to be repeated manually. 1. Place the transmission in the PARK or NEUTRAL position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 2. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 5. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as necessary. 6. Lower the vehicle to allow for entry and exit while bleeding the brake corners and other components. 7. Connect a battery charger to the 12V battery. The battery charger must remain connected for the entire automated bleed procedure. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) . 8. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during the entire automated bleed procedure. 9. Turn the ignition switch to the ON position with the engine OFF. Note Do not pressurize the pressure bleederJ-29532-A orJ 29532 , and thereby the master cylinder reservoir, until instructed to do so by the scan tool. 10. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions Page 14331 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 1924 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 2791 Fuse Block - I/P X2 (except MEX) Page 18540 Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 14522 4. Using theCH-48845 (1), compress the front spring (2). 5. Using the appropriate size wrench, hold the shock absorber shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 20989 Page 8317 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 8932 7. Remove the cable end from the steering column ball stud. 8. Depress the tangs and remove the cable from the steering column bracket. Note Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 9. Remove the range selector cable from the support. Page 1805 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 6249 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Page 649 Page 4376 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the exhaust heat shield nuts. 3. Remove both wheelhouse panels. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 4. Remove the exhaust heat shield (1, 3) from the dash panel studs. 5. Remove the heat shield (1, 3) through the respective wheelwell. Installation Procedure 1. Install the heat shields (1, 3) through the respective wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in) . 4. Lower the vehicle. Page 8081 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 9899 Page 10766 Page 2838 Junction Block - Left I/P X4 (except MEX) Page 9046 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13554 Junction Block - Left I/P X4 (except MEX) Page 1396 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 20839 Page 5822 - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the Powertrain High Speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the Powertrain High Speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * Powertrain High Speed GMLAN serial data circuit terminating resistors * Control module locations on the Powertrain High Speed GMLAN serial data circuits * Each control module's Powertrain High Speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the Powertrain High Speed GMLAN serial data circuit, refer toData Link References (See: Initial Inspection and Diagnostic Overview/Data Link References) . Communications should not be available with two or more control modules on the Powertrain High Speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer toDTC U0100-U0299 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100) . 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. Page 5823 ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 3 and terminal 11. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules Page 1873 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 16486 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1258 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12024 Fuse: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 13382 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Page 11725 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 8728 Page 13199 Page 1481 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 14833 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. Page 19402 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 19585 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 18547 Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Page 13284 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 8396 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 8061 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 7079 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 8252 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3358 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 10519 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 10483 Page 6913 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 2899 Page 13844 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 8927 Shift Cable: Adjustments Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 18817 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19548 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 10716 Electronic Brake Control Module (EBCM) (JL4 Except 10 Series) Page 1306 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 11931 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 13292 Fuse Block - Auxiliary X3 (HP2) Page 1422 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 8016 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor O-Ring - Seal 15 - Transfer Case Rear Half 16 - Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Actuator Shaft Position Sensor Bolt/Screw 22 - Transfer Case Actuator Shaft Position Sensor Assembly 23 - Transfer Case Actuator Shaft Position Sensor - O-Ring - Seal 24 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 25 - Transfer Case Two/Four Wheel Drive Actuator Assembly 26 - Transfer Case Two/Four Wheel Drive Actuator Seal 27 - Transfer Case Oil Drain Plug 28 - Transfer Case Oil Fill Plug 29 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 30 Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Internal Components Page 10718 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Page 16508 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6625 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17638 Endgate Emblem/Nameplate Replacement (Z71) Endgate Emblem/Nameplate Replacement (Z71) Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (Chevrolet) Page 10504 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 1292 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Page 8322 Page 10829 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) . Page 4867 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 1525 Page 771 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 7115 Page 10538 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 6267 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (4.8L/5.3L/6.2L/6.0L without ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (6.0L with ZW9) Page 5730 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 18552 Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Page 16545 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 7237 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Locations Seat Memory Switch: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 4831 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 5602 Page 5752 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 5616 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Disengage the engine wiring harness electrical connector retainers and remove the connectors (2) from the ECM (1). Page 332 Page 6460 2. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle. 3. Ensure that the EVAP canister vent solenoid engages the fuel tank bracket retainer (1). 4. Connect the EVAP vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 5. Install the EVAP vent solenoid pipe clip (1) to the frame crossmember. Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 15681 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10407 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 13057 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 12344 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Page 1273 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 13357 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 9077 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 2808 Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 11027 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Page 15976 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Left Rear Door Components (Extended Cab) Locations Fuse Block: Locations Harness Routing Views Driver Door Harness Routing 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Passenger Door Harness Routing 09-08-127-001 - END OF INFORMATION NEED Parking Assist Distance Sensor: All Technical Service Bulletins 09-08-127-001 - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-127-001B Date: August 10, 2009 Subject: EI09084 - Rear Parking Assist System Inoperative (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2009 Saturn OUTLOOK All Equipped with Rear Parking Assist (RPO UD7) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-127-001A (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp clip (2) from the air cleaner outlet duct (1). Page 10235 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8117 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 10420 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 19359 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 746 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 17830 Console: Service and Repair Center Console End Panel Replacement Center Console End Panel Replacement Floor Console Bezel Replacement Floor Console Bezel Replacement Page 16080 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Page 13010 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 3010 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 10547 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 8954 Disclaimer Page 2984 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Front Wheelhouse Liner Replacement - Left Side Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Left Side Front Wheelhouse Liner Replacement - Left Side (Chevrolet) Page 7222 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 16344 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2860 Junction Block - Rear Lamps X4 Page 16714 Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Page 5109 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Component Locations Air Bag Control Module: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: Customer Interest Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 15380 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Top of the Headliner Components (Regular Cab) Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 4360 Confirm the origin of the buzz by shimming (use metal shims) the straps tight and rerunning the vehicle. If the buzz concern is gone, then it is caused by the loose shield. Using the following procedure, install new straps to secure the heat shield to the muffler. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Mark the position of the heat shield (1) and straps (2) on the muffler shell. 3. Cut and remove the heat shield straps using tin snips along the muffler shell seam (1), and remove the shield from the muffler. 4. Position the heat shield to the muffler and install new heat shield straps on the muffler shell in the positions marked prior to removal. Important Do Not position the strap screw heads directly across from the propeller shaft. Ensure the strap heads are positioned below the midpoint of the muffler. 5. Position the strap screw heads (1) on the inboard side of the muffler. Ensure that the strap screw heads (1) are below the midpoint of the muffler. Tighten Tighten the straps to 4 Nm (35‹›lb‹›in). 6. Cut off the excess strap material and ensure that the ends (2) are flat against the muffler. Parts Information Page 9027 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Engine - Valve Lifter Tick Noise At Start Up Oil Filter: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 10298 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 504 HVAC Control Module X2 (CJ2) Page 3079 Page 18486 Power Seat Motor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 8210 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10972 Brake Drum: Removal and Replacement Brake Drum Replacement Special Tools J-42450-A - Wheel Hub Resurfacing Kit Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove and discard the brake drum retainers (1), if equipped. Page 2930 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Diagrams Neutral Safety Switch: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Page 2811 Rear Side Door Window Replacement (Crew Cab) Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Crew Cab) Rear Side Door Window Replacement (Crew Cab) Procedures Brake Master Cylinder: Procedures Master Cylinder Replacement (RHD) Master Cylinder Reservoir Filling (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Master Cylinder Replacement (Vacuum Boost) Master Cylinder Reservoir Filling (Two-mode Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Important: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Important: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Visually inspect the brake fluid level through the brake master cylinder reservoir. 4. The brake fluid level should rise to the upper full fill level mark (1) after the brake fluid level stabilizes. 5. If the brake fluid level is below or rises above the upper fill level mark after the brake fluid level stabilizes, the brake system should be inspected. Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Specifications Timing Cover: Specifications Front Cover Bolts.................................................................................................................................. ..........................................................25 Nm (18 lb ft) Page 9365 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft) . 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. Page 17634 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Hybrid 2 Mode) Endgate Emblem/Nameplate Replacement (HYBRID 2 Mode) Specifications Piston: Specifications Piston Rings Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore Production...............................................0.20-0.41 mm (0.0079-0.0161 in) Piston Ring End Gap First Compression Ring - Measured in Cylinder Bore Service.....................................................0.20-0.46 mm (0.0079-0.0181 in) Piston Ring End Gap Second Compression Ring - Measured in Cylinder Bore Production...........................................0.37-0.69 mm (0.0146-0.0272 in) Piston Ring End Gap Second Compression Ring - Measured in Cylinder Bore Service.................................................0.37-0.75 mm (0.0146-0.0295 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore Production..........................................................0.22-0.79 mm (0.0086-0.0311 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore Service................................................................0.22-0.84 mm (0.0086-0.0331 in) Piston Ring-to-Groove Clearance - First Compression Ring Production.........................................................................0.04-0.083 mm (0.0016-0.0033 in) Piston Ring-to-Groove Clearance - First Compression Ring Service..............................................................................0.04-0.083 mm (0.0016-0.0033 in) Piston Ring-to-Groove Clearance - Second Compression Ring Production..................................................................0.035-0.078 mm (0.0014-0.0031 in) Piston Ring-to-Groove Clearance - Second Compression Ring Service........................................................................0.035-0.078 mm (0.0014-0.0031 in) Piston Ring-to-Groove Clearance - Oil Control Ring Production.................................................................................0.013-0.201 mm (0.0005-0.0079 in) Piston Ring-to-Groove Clearance - Oil Control Ring Service.......................................................................................0.013-0.201 mm (0.0005-0.0079 in) Pistons and Pins Pin - Piston Pin Clearance- to-Piston Pin Bore Production...........................................................................................0.002-0.01 mm (0.00008-0.0004 in) Pin - Piston Pin Clearance-to-Piston Pin Bore Service................................................................................................0.002-0.015 mm (0.00008-0.0006 in) Pin - Piston Pin Diameter..................................................................................... ........................................................23.952-23.955 mm (0.9430-0.9431 in) Pin - Piston Pin Fit in Connecting Rod Bore Production.............................................................................................0.007-0.02 mm (0.00027-0.00078 in) Pin - Piston Pin Fit in Connecting Rod Bore Service................................................................................................0.007-0.022 mm (0.00027-0.00086 in) Piston - Piston Diameter - Measured Over Skirt Coating........................................................................................101.615-101.649 mm (4.0006-4.0019 in) Piston - Piston to Bore Clearance Production.................................................................................................-0.031 to +0.021 mm (-0.0012 to +0.0008 in) Piston - Piston to Bore Clearance - Service Limit With Skirt Coating Worn Off...................................................................................0.071 mm (0.0028 in) Page 18463 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 8856 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 2084 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 18729 Switch Position Icons Page 5245 Crankshaft Position (CKP) Sensor (Diesel) Page 7037 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Page 6860 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Page 2694 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Body Rear Inner Panel Carpet Replacement Carpet: Service and Repair Body Rear Inner Panel Carpet Replacement Body Rear Inner Panel Carpet Replacement Page 5733 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 8053 Devices and Sensors Page 3732 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 8585 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 6213 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 3633 12. Remove and discard the old gasket (1). Installation Procedure Note * All gasket surfaces should be free of oil an/or other foreign material during assembly. * DO NOT reuse the valve rocker arm cover gasket. * If the PCV valve grommet has been removed from the rocker cover, install a NEW grommet during assembly. 1. Install a NEW rocker cover gasket (1). Page 12474 Page 5453 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 6265 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 1514 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. Page 5689 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 6542 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 5284 kPa (43 - 45 psi). Circuit/System Testing Important: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from theCH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with theCH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (2500/3500 Regular Cab) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair )Fuel Hose/Pipes Replacement - Chassis (2500/3500 Crew Cab) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Regular Cab) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement Chassis (2500/3500 Extended Cab) (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026B Date: April 07, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2010 model year and information about retrieving calibrations on a Global A vehicle. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine, transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 10419 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 18548 Front Center Seat Back Cushion Latch Replacement (AZ3) Front Center Seat Back Cushion Latch Replacement (AZ3) Page 16182 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 8871 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 14037 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9559 One-Piece Propeller Shaft 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer 8 Propeller Shaft Bearing Retainer Bolt Two-Piece Propeller Shaft Two-Piece Propeller Shaft 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Bearing Shield 6 Propeller Shaft Bearing Insulator 7 - Propeller Shaft Bearing Support Bolt 8 - Propeller Shaft Bearing Support 9 - Propeller Shaft Retainer 10 - Propeller Shaft Center Support Bearing 11 Propeller Shaft Retainer 12 - Propeller Shaft Bearing Slinger 13 - Propeller Shaft Universal Joint Page 10418 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 17116 Page 12025 Page 2008 Seat Occupant Sensor: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) Page 18632 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 15055 Page 10306 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Page 17320 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Page 5216 Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas Except 4.3L/LY6) Page 20512 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12564 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8228 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 9674 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 8470 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 18254 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7342 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 12254 Junction Block - Rear Lamps X4 Drivetrain - Magna Transfer Case Service Parts Info. Shift Fork: Technical Service Bulletins Drivetrain - Magna Transfer Case Service Parts Info. INFORMATION Bulletin No.: 09-04-21-006 Date: October 29, 2009 Subject: Information on Magna Transfer Case Service Parts for Control Actuator Levers Models: 2007-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL All Equipped with Magna MP3023 Two-Speed Active Transfer Case (RPO NQH) or MP3010 Single-Speed Active Transfer Case (RPO NQH and NP0) Note Heavy duty (HD) components are the only parts available for service. The purpose of this bulletin is to provide information regarding the servicing of the Light Duty (LD) transfer cases. LD Transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Note Light Duty (LD) 2007-2010 MP3023-NQH and 2010 MP3010-NP0 transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Additional component dimensional information can be obtained within the applicable Transfer Case Description and Operation/Build Variations section of SI. When replacement of one or both of the LD control actuator levers is required, it is necessary to replace both of the levers and all three balls with the HD components as a set. It is also necessary to re-measure and adjust clutch pack clearances as required and to perform the Transfer Case High/Low Clutch Reset. Refer to Measuring/Adjusting Clutch Assembly Height in Transfer Case Assemble, Transfer Case Description and Operation and Transfer Case High/Low Clutch Reset. Refer to the table below for information regarding the HD design part numbers. Parts Information Disclaimer Page 3083 Fuse Block - Underhood X4 Page 1767 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 REG Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 4953 Page 20896 2. Remove the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. Note The underhood fuse block is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 3. Locate the underhood bussed electrical center (UBEC) (2). 4. Remove the UBEC cover (2) and locate the WSW/HTR 60 amp heated windshield washer fuse. 5. Remove the WSW/HTR 60 amp heated windshield washer fuse (3) using pliers. 6. Discard the WSW/HTR 60 amp heated windshield washer fuse (3). 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Install the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Page 14070 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 16517 Involved are certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles built within the VIN breakpoints above. Important: Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.- GM dealers and Canadian Saturn retailers should use GMVIS.- Saturn US retailers should use the "Investigate Vehicle History" link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information Valve Lifter Oil Filter Replacement Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Filter Replacement Valve Lifter Oil Filter Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Remove the oil pressure sensor (1) and washer (2). 4. Remove and discard the valve lifter oil filter (3). 5. Remove and discard the valve lifter oil filter O-ring seal (4). Installation Procedure Page 13156 Fuse Block - Underhood X4 Page 13436 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 12132 Junction Block - Rear Lamps X1 Page 12989 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 8251 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 767 Page 13346 Page 12412 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 13794 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 18555 Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Page 17252 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Page 14057 Alignment: Specifications Trim Height Specifications Trim Height Specifications Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Page 15312 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 16475 Disclaimer Page 14220 4. Install the new idler arm nut (3) to the idler arm (1) and tighten to 62 Nm (46 lb ft) . 5. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 6. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 11596 7. Working through the wheel opening, remove the positive battery cable clip (2) from the brake pipe. 8. Working through the wheel opening, remove the positive battery cable clip (3) from the air cleaner adapter bracket 9. Lower the vehicle. 10. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 11. Remove the positive battery cable clip (4) from the air cleaner support bracket. 12. Remove the positive battery cable clip (5) from the fender inner panel. 13. Disconnect the positive battery cable electrical connector (1) from the drive motor generator control module. 14. Remove the positive battery cable (1) from the vehicle. Installation Procedure Page 8254 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 5496 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 5680 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 11510 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 Except 10 Series) Page 15568 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Page 13595 Fuse Block - Underhood X5 Page 20543 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 13503 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 11326 13. Connect the J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent, to the J-35589-A - Brake Pressure Bleeder Adapter, or equivalent . 14. Set the pressure regulator of the J-29532-A - Brake Pressure Bleeder , or charge the air tank of the J-29532 - Diaphragm Pressure Bleeder , to 200 kPa (30 psi). 15. Open the J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 16. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 17. Use the following sequence for bleeding the wheel hydraulic circuits: * Right rear * Left rear * Right front * Left front 18. Install a proper box-end wrench onto the appropriate wheel hydraulic circuit bleeder valve. 19. Secure a transparent bleeder hose to the bleeder valve. 20. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 21. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow for 30 seconds, or until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 22. With the first wheel hydraulic circuit bleeder valve tightened securely, repeat steps 18-21 for the remaining wheel hydraulic circuits in the proper sequence. 23. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 24. Close the J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent, fluid tank valve, then disconnect the J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent, from the J-35589-A - Brake Pressure Bleeder Adapter, or equivalent . 25. Remove the J-35589-A - Brake Pressure Bleeder Adapter, or equivalent from the brake master cylinder reservoir. 26. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 27. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. Note If it is determined that air was introduced into the system upstream of the ABS modulator prior to servicing, theAntilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair) must be performed. 28. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (See: Brake Bleeding/Service and Repair) . 29. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 30. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Power Brake Booster Outlet Front Pipe Replacement Power Brake Booster Pump Fluid Accumulator Replacement (Non-Hybrid) Special Tools J-26889 - Accumulator Piston Compressor Removal Procedure Warning Page 12483 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 5884 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (6.0L with ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.3L) Page 387 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in) . 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . Page 9687 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Engine Oil Cooler Connector Replacement Oil Cooler: Service and Repair Engine Oil Cooler Connector Replacement Engine Oil Cooler Connector Replacement Page 4651 10. Remove the PIM cover retaining bolts (1). 11. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 12. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Page 19112 Air Dam: Service and Repair Front Air Deflector Replacement (GMC) Front Air Deflector Replacement (GMC) Page 1047 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 10439 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 20764 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5657 Switch Position Icons Page 1902 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 6962 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 80 Disclaimer Page 19024 For vehicles repaired under warranty, use the table. Disclaimer Page 17083 Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 10194 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Valve Body: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 18960 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) Page 9001 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 19070 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Page 9582 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the center bearing support nuts. Tighten the center support bearing nuts to 40 Nm (30 lb ft). 7. Tighten the propeller shaft bolts (3) to specifications. Tighten the propeller shaft bolts to 25 Nm (18 lb ft). 8. Install the boot (3) and the new clamps (2) onto the front propeller shaft slip yoke (4). Note Ensure that the master splines on the slip yoke and the stub shaft are aligned before installing the rear propeller shaft. OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 4000 14. Remove the CMP sensor (703). 15. Remove the CMP actuator magnet bolts (751), and magnet (752). 16. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note * Do not reuse the crankshaft oil seal or front cover gasket. * Do not apply any type of sealant to the front cover gasket, unless specified. * The special tool in this procedure is used to properly center the front crankshaft front oil seal. - All gasket surfaces should be free of oil or other foreign material during assembly. - The crankshaft front oil seal MUST be centered in relation to the crankshaft. - An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks. Page 6643 Fuel Injector 5 (4.3L) Fuel Injector 5 (4.8L/5.3L/6.0L/6.2L) Page 14707 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 6239 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 5706 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 12016 Fuse Block - Auxiliary X1 (HP2) Page 8179 Page 12654 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 9120 Disclaimer Page 17334 Page 438 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 14453 4. Tighten the steering linkage inner tie rod using wrenchCH-49009 . Tighten the steering linkage inner tie rod to 145 Nm (107 lb ft). 5. Align the new steering linkage inner tie rod washer (1) to the flats on the steering linkage inner tie rod and bend the tabs over the flats. Note The appropriate grease must be applied to the small end of the steering gear boot before installation. 6. Install the steering gear boot. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair) . Page 9894 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 4973 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 16995 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 2089 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 7974 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7763 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 1750 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Locations Braking Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 10649 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 3645 15. Position the generator battery cable as necessary. 16. Install the generator battery cable clip (1) to the ignition coil bracket stud. 17. Position the engine wiring harness (electronic throttle control branch) as necessary. 18. Install the engine wiring harness (electronic throttle control branch) clip to the ignition coil bracket stud. 19. Connect the engine harness electrical connector (1) to the ignition coil wire harness. 20. Install the CPA retainer (2). Page 20243 Page 6952 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 15059 Page 16834 Disclaimer Page 4957 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Relays and Modules - Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 5097 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 18257 For vehicles repaired under warranty, use the table. Disclaimer Page 7785 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 11320 Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) dirty air hose from the intake manifold fitting and left valve rocker arm cover, if required. 3. Remove the PCV fresh air tube (1) from the air cleaner outlet duct, if required. Page 12430 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 19595 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8196 Page 3945 9. Remove the J 22794 from the spark plug port. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 10. Hand start the spark plug. Tighten the spark plug to 15 Nm (11 lb ft). 11. Install the spark plug wires at the ignition coil. 12. Install the spark plug wire to the spark plug. 13. Inspect the wires for proper installation: * Push sideways on each boot in order to check for proper installation. * Reinstall any loose boot. 14. Install the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair) . Page 5490 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Page 8565 3. Install the range selector lever cable (2) to the cable bracket. 4. Install the range selector lever cable retainer (1). 5. Connect the range selector lever cable (2) to the range select lever. 6. Install the range selector lever cable heat shield (2). 7. Install the range selector lever cable heat shield bolts (1). Tighten the bolts to 17 Nm (13 lb ft). 8. Lower the vehicle. Page 4580 Page 18606 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 9879 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Page 11086 Note To ensure brake modulator and HPA pressure relief has occurred, the manual pressure relief valve must be opened momentarily. 7. Loosen the brake modulator manual pressure relief valve (1) 1/4 turn counterclockwise. 8. Seat, but do not tighten, the manual pressure relief valve. 9. Disconnect the electronic brake control module (EBCM) electrical connector. 10. Disconnect the electronic brake control position sensor electrical connector. 11. Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination. Locations Keyless Entry Receiver: Locations Passenger Compartment/Roof Component Views Rear of the Passenger Compartment Components 1 - Information Center Telltale Assembly (UD7) 2 - Sliding Rear Window Open Relay (A48) 3 Sliding Rear Window Close Relay (A48) 4 - Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) 5 - Sliding Rear Window Motor (A48) Page 20939 Page 6986 Ignition Coil: Diagrams Component Connector End Views Ignition Coil 1 (4.8L/5.3L/6.0L/6.2L) Ignition Coil 2 (4.8L/5.3L/6.0L/6.2L) Page 18495 Seat Recline Motor - Passenger (AN3) Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Page 17263 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Page 11750 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 1446 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 19241 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair ) orRear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 7. Inspect the door closing effort and seal to door fit. Page 3981 11. Remove the crankshaft sprocket key, if required. Installation Procedure 1. Install the key into the crankshaft keyway, if previously removed. 2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft. Page 18627 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 17410 Disclaimer Page 6887 Page 8549 7. Connect the auxiliary fluid pump wire harness (1) to the auxiliary fluid pump control module connector (2). Caution: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage. 8. Fill the transmission with the proper amount of transmission fluid. Refer to Fluid Capacity Specifications (See: Specifications/Capacity Specifications) andTransmission Fluid Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Check ) . Page 14085 Steering Control Module: Service and Repair Electronic Power Steering Motor Control Module Replacement Page 3303 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5402 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 9250 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Page 6337 Page 19527 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 5414 Auxiliary Body Control Module (XBCM) X1 (EXP) Page 6279 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 6. Remove the HO2S (1). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (1). Tighten the sensor to 42 Nm (31 lb ft). Page 1435 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 4304 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 4745 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 13525 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 17149 Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Page 11633 Harness Components Page 3309 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 4554 1. Install new APM coolant seal (3). 2. Position the APM (2) onto the PIM ensuring the seals remain in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the APM mounting fasteners (1). Tighten the mounting fasteners to 10 Nm (89 lb in) . 4. Rotate the drive motor generator control module assembly onto the APM. 5. Clamp GE-48494 adapter kit components (2, 3) to a coolant pipe. 6. Plug the remaining coolant pipe with GE-48494 adapter kit plug and clamp (1). 7. Apply20 psi (138 kPa) pressure with J 24460-01 - pressure tester (4). 8. Monitor the pressure tester gauge for 5 minutes and ensure that pressure remains at the specified value. * If the specified pressure cannot be maintained, disassemble the drive motor generator control module assembly and replace the coolant seals. * If pressure remains at the specified value, proceed to the next step. 9. Remove all GE-48494 - adapter kit components. Page 2997 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 7159 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 12729 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Procedures Parking Brake Cable: Procedures Parking Brake Cable Adjuster Disabling Parking Brake Cable Adjuster Disabling Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure, one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a thin tool (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Parking Brake Cable Adjuster Enabling Parking Brake Cable Adjuster Enabling 1. Hold the park brake pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the tension is released from the tool (1) installed in the pedal assembly. 3. Remove the tool (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. Page 16929 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11639 Devices and Sensors Page 8262 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 4466 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 17354 1. Install the door upper striker (4). 2. Install the spacer, if equipped. 3. Install the door upper striker bolt (3). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Tighten the upper striker bolts. Tighten the door upper striker bolts to 24 Nm (18 lb ft). 6. Install the upper trim door upper striker cover. Ensure that the retainer clips were Not damaged when removed. Push upward into locator holes. Page 6634 Fuel Injector 1 (Diesel) Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - M/T: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20002 Page 13584 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 13021 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 9812 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 19575 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 10909 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 6870 Page 5780 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 17158 Trailer Brake Control Module (JL1 with 31 Series) Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 20384 Park/Turn Signal Lamp - Upper Right Page 6874 Page 3451 Compression Check: Testing and Inspection Engine Compression Test Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. Note When performing an engine cylinder compression test for the RPO-LFA engine, note that this engine has a camshaft position actuator with a late intake valve closing feature and a 29 degree retard park position. With the actuator parked in a retard position, the effective compression of the engine is reduced during cranking. Compression values on the gage will be lower than a typical small block engine that does not have this feature. 1. Review the system operation in order to familiarize yourself with the system functions. As required, disable the auto-stop function prior to repair. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition key in the OFF position. 3. Charge the battery if the battery is not fully charged. 4. Disable the fuel and spark by removing the Fuel Pump relay and Powertrain relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) for the Fuse Block - Underhood Label. 5. Remove the spark plug wires from the spark plugs. 6. Remove all of the spark plugs. Warning Do not leave the ignition key in the ON position after the test is performed. Leaving the key in the ON position may result in an Auto-Start of the engine and possible personal injury. 7. Install a compression gage to the cylinder to be tested. 8. Start with the compression gage at zero and crank the engine 3-5 seconds using the ignition key. 9. Return the ignition key to the OFF position. 10. Measure the compression for each cylinder. Record the readings. 11. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any 1 cylinder is 862 kPa (125 psi), the lowest allowable pressure for any other cylinder would be 607 kPa (88 psi). (862 kPa x 70% = 607 kPa) (125 psi x 70% = 88 psi). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. 12. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 13. Reinstall the Fuel Pump relay and Powertrain relay. 14. Using the scan tool, clear all diagnostic codes. Page 5739 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3434 CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft, through the 4X signal of the CMP sensor. If the difference between the actual and the desired position is greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Page 20364 Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Page 2085 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 19756 Disclaimer Page 19681 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. Total Fuel Saved (Hybrid) Fuel Saved Over Lifetime shows how much fuel (by volume) was save by driving the Hybrid versus the non-Hybrid (if equipped). This value constantly accumulates over the life of the vehicle and is not re-settable. Fuel Saved Since Reset The Fuel Saved Since Reset is similar to the Fuel Saved Over Lifetime but is re-settable by the driver. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the DIC Vehicle Info switch. Trip Odometer The trip odometer can be accessed through the DIC Trip/Fuel switch function. The trip odometer shows the current distance traveled in either miles or kilometers since the last reset of the trip odometer. The trip odometer can be reset to zero by pressing the set/reset button while the trip odometer is displayed. The trip odometer has a feature called the retro-active reset. This can be used to set the trip odometer to the number of miles (kilometers) driven since the ignition was last turned on. This can be used if the trip odometer is not reset at the beginning of the trip. To use the retro-active reset feature, press and hold the set/reset button for at least four seconds. The trip odometer will display the number of miles (mi) or kilometers (km) driven since the ignition was last turned on and the vehicle was moving. Once the vehicle begins moving, the trip odometer will accumulate mileage. Language The DIC is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Compass The driver information center (DIC) displays the compass based on serial data message from the BCM. The compass module communicates with the body control module (BCM) through a bi-directional data circuit. The instrument panel cluster (IPC) receives compass information from the BCM via the serial data circuit. The compass is displayed in the DIC with other vehicle information and is at the bottom line of the DIC. The compass display shows "- -" when a malfunction is present with the compass module or a compass serial data communication fault exists. The compass displays 'CAL' or 'C' when the compass needs to be calibrated. Cycle the ignition before performing the compass magnetic variation adjustment procedure. Check that the compass module is properly installed in the vehicle since this may cause the compass to malfunction. The embossed arrow on the top of the compass module should be parallel to the centerline of the vehicle. Outside Air Temperature The Outside Air Temperature is sent via the serial data circuit from the BCM to the IPC. It is displayed in the lower left corner of the DIC. It is displayed in the English and Metric units Page 7740 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 14554 7. Remove the torsion bar crossmember bolt (4) from the weld nut (1). 8. Remove the crossmember (2) from the crossmember mount (3). 9. Remove the torsion bar from the crossmember. Note The left and right torsion bars are different and are not interchangeable. 10. Remove the torsion bars from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the crossmember (2) on the crossmember mount (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the torsion bar crossmember bolt (4) in the weld nut (1) and tighten to 110 Nm (81 lb ft). . 4. Install the adjustment arm (2) in the crossmember (1). 5. Install the adjuster bolt (3) and the adjuster nut (4). 6. Install the torsion bar into the adjustment arm until the torsion bar is fully seated. Page 566 Page 13222 Junction Block - Left I/P X2 (except MEX) Page 2787 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 17665 For vehicles repaired under warranty, use the table. Disclaimer Page 1633 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 6398 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 5201 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 4674 Note The sight shield mounting fastener must be installed and tightened. Failure to properly tighten the sight shield mounting fastener may result in an open High Voltage Interlock Circuit (HVIC) condition and DTCs. 1. Install the sight shield onto the ball studs (2) and tighten the sight shield mounting fastener (1). Tighten the fastener to 5 Nm (44 lb in) . 2. Install the fender brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 3. Enable high voltage. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 1024 Page 3015 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 8208 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 2830 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2555 Engine Oil: Fluid Type Specifications ENGINE OIL Look for three things: 1. Use only an oil that meets GM Standard GM6094M. 2. Temperatures above -20°F (-29°C), SAE 5W-30 is best for the vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50 or any other viscosity grade oil not recommended. 3. American Petroleum Institute (API) starburst symbol Oils meeting these requirements should have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Notice: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by the vehicle warranty. COLD TEMPERATURE OPERATION If in an area of extreme cold, where the temperature falls below -20°F (-29°C), use either an SAE 5W-30 synthetic oil or an SAE 0W-30 engine oil. Both provide easier cold starting for the engine at extremely low temperatures. Always use an oil that meets the required specification, GM6094M. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all that is needed for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Page 13149 Fuse Block - Underhood X1 Page 12191 Page 15441 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection * Vehicles involved in accidents which result in the following conditions may also have a damaged or misaligned steering column: - Frame damage - Major body or sheet metal damage - Where the steering column has been impacted - Where supplemental inflatable restraint systems deployed * Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. * Inspect for jacket assembly collapse by measuring the distance from the steering column support bracket mounting plate (1) to the lower edge of the jacket lower bracket (2). Replace the jacket assembly if the measured dimensions are less than 286 mm. Page 5792 Information Bus: Connector Views Component Connector End Views Serial Data Gateway (SDG) Module X1 (HP2) Serial Data Gateway (SDG) Module X2 (HP2) Page 9301 - Select "Z" - Select "Aura" - Select "Powertrain" - Select "3.6L LY7" - Select "Transmission" - Select "Transmission Data" 5. From the application menu, select F3: Snapshot. - Choose trigger type and trigger point, as described above. - It is preferred to trigger on "Any Code" (F1) - If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on the next screen. - Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the events before and after the code sets. 6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going to record for live viewing. - When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1 and F5) are selected. - If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key to actually record data. Otherwise, it will automatically start recording when a DTC is set. - Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1 minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is selected). Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third snapshot is requested, the first snapshot will be overwritten. 7. When the snap shot data has been recorded, exit to the Main Menu, then power down and disconnect the Tech 2(R) from the vehicle. Uploading and Sending a Snapshot via TIS2WEB Figure 8 Page 12168 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 1143 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Page 10339 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2832 Junction Block - Left I/P X1 (except MEX) Page 6578 Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis (Without Special Tool) Alcohol/Contaminants-in-Fuel Diagnosis (without Special Tool) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Alcohol in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.4 oz) specified cylinder with 1 ml (0.03 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.4 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 liter (0.13 gal) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. If particles are found clean the entire fuel system thoroughly. Component Locations Trailer Connector: Component Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 4525 Drive Motor Generator Battery Control Module X3 (HP2) 09-08-127-001 - END OF INFORMATION NEED Parking Assist Distance Sensor: All Technical Service Bulletins 09-08-127-001 - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-127-001B Date: August 10, 2009 Subject: EI09084 - Rear Parking Assist System Inoperative (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2009 Saturn OUTLOOK All Equipped with Rear Parking Assist (RPO UD7) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-127-001A (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 14369 1. Install the steering linkage shock absorber (2) to the vehicle. 2. Install the steering linkage shock absorber (4) and nuts (1, 3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the steering linkage shock absorber nuts (1, 3) and tighten to 40 Nm (30 lb ft) . 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 4031 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis (W/O FPCM) Fuel System Diagnosis (w/o FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Fuel Pressure Gage * J 37287 Fuel Line Shut-Off Adapters Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer toFuel System Diagnosis (w/o FPCM) Fuel System Diagnosis (w/FPCM) (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 2. Ignition OFF, all accessories OFF, install theCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 3. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: Page 10177 Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Page 890 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 4664 Drive Motor Generator Battery Control Module X2 (HP2) Page 18337 Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 3. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 4. Remove the 1 hose clips securing the drain hose to the windshield pillar, right or left side, as needed. 5. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Install the drain hose by passing it threw the front of the dash panel. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 1 hose clips securing the drain hose to the side door frame, right or left side, as needed. 4. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 5. Install the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Page 20116 Page 9755 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 7761 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 8647 Page 20827 Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 11694 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 18041 Page 11428 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 3446 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . 2. Remove and discard the CMP actuator solenoid valve. Installation Procedure Page 15550 Page 96 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 11448 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 20196 Voice Recognition System - Won't Recognize Bluetooth(R) Steering Mounted Controls Communication Module: Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 20658 Window Switch - Driver X2 (A31 without AN3/DL3) Page 453 5. Slide the trailer brake control module (1) toward the center of the vehicle and remove the trailer brake control module. Installation Procedure 1. If installing a new trailer brake control module, hand start the 3 trailer brake control module bolts. 2. Position the trailer brake control module to the frame bracket. 3. Slide the trailer brake control module (1) toward the left frame rail. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 9247 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 6336 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30/TZ0/MYC or MW7/M99 with NQG/NQF) Vehicle Speed Sensor (VSS) (MW7 Except NQG/NQF) Page 5232 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 7518 Disclaimer Page 18762 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 5177 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LFA) engine, the park position for the CMP actuator and camshaft is 14.5 degrees after top dead center (ATDC), or 29 crankshaft degrees ATDC. The engine control module (ECM) can only command the CMP actuator to advance the valve timing from the park position, or retard the valve timing back to the park position. The total range of valve timing authority is 23 degrees camshaft rotation, or 46 degrees of crankshaft rotation. The control range is from the park position of 14.5 degrees camshaft, or 29 degrees crankshaft ATDC, to 8.5 degrees camshaft or 17 degrees crankshaft before top dead center (BTDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for CAM advance and a passage for CAM retard. The camshaft actuator is attached to the front of the camshaft, and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature, engine oil level, and aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostic The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control, DTC P0010 will set. Page 4789 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 8184 Page 19381 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Actuator: Locations Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) 1 - Output Shaft 2 - Pinion Bearing Spacer 3 - Pinion Head Bearing Assembly 4 - Pinion Shim 5 Stem Pinion 6 - Pinion Flange Nut 7 - Pinion Flange Washer 8 - Pinion Flange Assembly 9 - Pinion Seal 10 - Pinion Tail Bearing Assembly 11 - Carrier Housing 12 - Output Shaft Seal Assembly 13 Output Shaft 14 - Drain Plug Assembly 15 - Drain Plug Washer 16 - Fill Plug Assembly 17 - Fill Plug O-ring Seal 18 - Carrier Locator Pin 19 - Vent Connector 20 - Differential Case 21 - Ring Gear 22 - Output Shaft Bearing Assembly 23 - 8-Point Lock Ring 24 - Sleeve and Insert Assembly 25 Differential Side Bearing Assembly 26 - Differential Cross Pin Lock Page 15394 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 1932 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 18732 Page 8771 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2221 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5800 High Speed Bus - 5 of 6 (HP2) Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13240 Junction Block - Right I/P X3 Page 9368 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities andAdhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft) . 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Page 5435 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 20771 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 4663 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 16827 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 17383 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Locations Fuel Pressure Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 7711 Module Circuit Function Icons Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 19425 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 20780 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Page 19051 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 9813 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 1979 Page 7788 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Driver Information Display Switch Replacement (without RPO SLT) Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Page 416 Electronic Brake Control Module (EBCM) (JF3/JF7) Page 18753 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 4021 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Camshaft Position Actuator Solenoid Valve Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Remove the camshaft position (CMP) actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . 2. Remove and discard the CMP actuator solenoid valve. Installation Procedure Page 8069 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 7221 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Page 13500 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 20192 Page 10636 Page 3032 Fuse Block - Mobile Radio (9L4) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 16703 Speaker - Left Rear (Extended Cab/Crew Cab with UQ3/UQ5) Speaker - Left Rear (Extended Cab/Crew Cab with UQA) Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5665 Devices and Sensors Page 20985 Wiper Motor: Service and Repair Windshield Wiper System Module Replacement Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 11133 6. Connect the brake master cylinder right supply brake pipe fitting (1). Tighten the fitting to 30 Nm (22 lb ft). 7. Connect the brake master cylinder left supply brake pipe fitting (1). Tighten the fitting to 30 Nm (22 lb ft). Page 13702 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 19358 Page 3093 Fuse Block - I/P X2 (except MEX) Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 16226 Disclaimer Page 2621 Fuse Block - Auxiliary (HP2), Bottom View Page 20470 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 15958 Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)) . 19. Cut the seat belt pretensioner connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together one end from each of the wires in order to short the wires. The deployment wires are to remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 24. Twist together one connector wire lead to one deployment wire. 25. Inspect that the previous connection is secure. 26. Bend flat the twisted connection. 27. Secure and insulate the connection using electrical tape. 28. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Page 3845 18. Remove the 2 lower transmission bolts (1). 19. Disconnect the engine harness electrical connector (1) from the oil level sensor. Page 6562 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 11105 7. Remove the master cylinder return hose fitting (1). 8. Remove the master cylinder supply hose fitting (2). 9. Remove and discard the O-ring seals. 10. Remove the brake pipe manifold bolts (1). Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11718 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 5598 Electrical - Various Rear Door Electrical Malfunctions Speaker: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 13737 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Page 1326 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 17114 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 Except 31 Series) Page 15459 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Page 13537 Fuse Block - Auxiliary X1 (HP2) Body - Outside Door Handle Pulls Out of Base Front Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 11709 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 2354 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 3098 Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 1717 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 872 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions) . 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Page 10138 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor O-Ring - Seal 15 - Transfer Case Rear Half 16 - Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Actuator Shaft Position Sensor Bolt/Screw 22 - Transfer Case Actuator Shaft Position Sensor Assembly 23 - Transfer Case Actuator Shaft Position Sensor - O-Ring - Seal 24 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 25 - Transfer Case Two/Four Wheel Drive Actuator Assembly 26 - Transfer Case Two/Four Wheel Drive Actuator Seal 27 - Transfer Case Oil Drain Plug 28 - Transfer Case Oil Fill Plug 29 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 30 Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Internal Components Page 231 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Page 4210 Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Page 2737 Fuse 39 ................................................................................................................................................ ..................................... Climate Controls (Battery) Fuse 40 ............................................................... ........................................................................................................................ Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Fuse 71 ................................. .............................................................................................................................................................. ................. Not Used Fuse 72 .............................................................................................................. ............................................................... Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Page 5690 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7757 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 10873 Page 19576 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 1746 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 10172 Page 647 Body Control Module (BCM) X3 Page 6929 1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil. 2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting. 3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel pressure sensor to the fuel line and tighten the sensor to 15 Nm (11 lb ft) . 5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor. 6. Lower the vehicle. 7. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Page 19409 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 7292 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 2747 Page 2683 Fuse Block - Underhood X2 Page 18277 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in) . 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . Page 11926 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15428 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Page 20504 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 14342 * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Note If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 2691 Page 2859 Junction Block - Rear Lamps X3 Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 13164 Fuse Block - I/P Top View Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Page 10388 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 1891 Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas Except 4.3L/LY6) Page 13767 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Console Harness (Y91/UQA/D07) Page 7253 Page 15585 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Passenger Door Components (except AN3/DL3) Page 20258 Page 20177 Page 4071 Spark Plug: Application and ID Ignition System Specifications Page 16365 Disclaimer Page 14960 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2/C67) Page 9742 Disclaimer Page 18891 Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Page 12113 Junction Block - Left I/P X9 (except MEX) Page 5998 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 18057 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 18775 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Page 18989 For vehicles repaired under warranty, use the table. Disclaimer Page 6978 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. If replacing the right side spark plug wire(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug wire(s) through the wheel opening. 2. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 3. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Page 5842 Page 11678 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 13887 Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 15066 A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 19243 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Note Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Page 2807 Fuse Block - Underhood X2 Page 19584 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 13849 X278 Inline Harness Connector End Views X278 Instrument Panel harness to Body harness (MEX/A52) Lighting - Dome/Reading Lamps Inoperative Map Lamp: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 6205 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 15118 Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 6659 4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid (3). 5. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 6. Remove the connector position assurance (CPA) retainer (2). 7. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector. 8. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following: 1. Mark the connectors to their corresponding injectors to ensure correct reassembly. 2. Pull the CPA retainer on the connector up 1 click. 3. Push the tab on the connector in. 4. Disconnect the fuel injector electrical connector. 9. Remove the engine wiring harness clip (4) from the ignition coil bracket stud. Page 1266 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Page 16860 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 18765 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 5497 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 13995 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 12943 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Page 448 Trailer Brake Control Module (JL1 with 31 Series) Page 18788 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4143 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 6102 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor Replacement Page 5191 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 2629 Page 18760 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7227 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 20484 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Interior - Lint Accumulation On Ebony Colored Seats Seat Cover: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 19393 View of the connector when released from the component. View of another type of Micro 64 connector. Page 15001 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 3960 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 11087 12. Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination. 13. Disconnect the right rear brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 14. Disconnect the left rear brake pipe fitting (2). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 8797 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 7598 Page 6495 21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 Nm (18 lb ft). 22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 23. Lower the vehicle. 24. Remove the caps from the fuel rail and EVAP line. 25. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 26. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 27. Install the fuel fill cap. 28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 12803 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12157 Page 10923 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 8777 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6157 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: All Technical Service Bulletins Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 20368 Page 11264 6. Remove the intermediate park brake cable. Installation Procedure 1. Connect the left park brake cable (1) and the right park brake cable (2) to the equalizer bar (3) on the intermediate park brake cable. 2. Connect the front park brake cable (2) to the intermediate cable connector. 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling) . 4. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Parking Brake Rear Cable Replacement - Left Side (JD9) Parking Brake Rear Cable Replacement - Left Side (JD9) Page 11816 Switches and Relays Page 8747 Page 16254 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 2696 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 1010 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 19419 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 7163 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 7059 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 11549 Page 20598 Sliding Rear Window Motor (A48) Sliding Rear Window Open Relay (A48) Page 3055 Junction Block - Right I/P (Wire Entry) Page 4719 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 17560 5. Remove the rear sliding window motor/module nuts (2). 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Page 19482 Page 20826 Page 12670 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 13243 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 11061 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (2500 Series) Rear Brake Hose Replacement (Caliper - JD9) Page 12116 Junction Block - Left I/P X12 (except MEX) Page 8481 Page 2641 Fuse Block - Underhood X2 Page 3684 2. Install and tighten the drive belt tensioner bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt/Service and Repair/Drive Belt Replacement Accessory) . Page 17855 Glove Compartment: Service and Repair Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Page 35 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 6085 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 2658 Fuse Block - I/P X3 Page 10712 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Page 12857 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 12240 Junction Block - Left I/P X13 (AN3) Page 10725 1. Position the EBCM (1) to the BPMV. 2. Push the EBCM squarely onto the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the EBCM bolts (1) and tighten in a cross pattern to 3 Nm (27 lb in) . 4. Connect the EBCM electrical connector. 5. If installing a new EBCM, the EBCM must be programmed and the sensor and boost valve calibration and EBCM learn processes must be performed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 10563 Page 14407 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 69 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 9491 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Page 4788 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 18820 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 5632 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 2769 Fuse Block - Underhood X4 Page 10877 Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6561 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 20526 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: Customer Interest Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 19384 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 8241 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 3437 1. Install a NEW CMP actuator magnet gasket (753) onto the CMP actuator magnet. 2. Install the CMP actuator magnet (752) to the front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the CMP actuator magnet bolts (751). Tighten the bolts to 12 Nm (106 lb in). 4. Connect the engine harness electrical connector to the CMP actuator magnet. 5. Install the water pump. Refer to Water Pump Replacement . Page 2772 Page 15155 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 15499 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5270 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 13494 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Control Solenoid Valve and Transmission Control Module Assembly Replacement Extension Housing: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission fluid filter and auxiliary fluid pump filter. Refer to Automatic Transmission Fluid Filter and Auxiliary Fluid Pump Filter Replacement (See: Service and Repair/Removal and Replacement) . 2. Remove the transmission electrical connector passage sleeve. Refer to Automatic Transmission Electrical Connector Passage Sleeve Replacement (See: Wiring Harness/Service and Repair/Automatic Transmission Electrical Connector Passage Sleeve Replacement) . 3. Remove the transmission wiring harness from the wire harness retainer (2). 4. Remove the transmission wiring harness connector (1) from the wire harness retainer. 5. Disconnect the transmission wiring harness from the control solenoid valve body (3). Page 2540 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 20649 Door Lock/Window Switch - Driver X7 (AN3/DL3) Page 13340 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 19580 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 12444 Junction Block - Left I/P X11 (except MEX) Page 8478 Transmission Control Module (TCM) (MW7) Page 17948 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Page 16269 Page 12142 Fuse Block - I/P X2 (except MEX) Page 16922 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 1818 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (6.0L with ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.3L) Page 1969 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended/Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Page 427 10. Remove the EBCM bolts (1). 11. Remove the EBCM (1). Installation Procedure Page 2655 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 10142 10 - Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4) 11 - Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plate (Qty: 7) 12 - Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plate (Qty: 8) 13 - Transfer Case Four Wheel Drive Clutch Hub 14 Transfer Case Four Wheel Drive Clutch Shim 15 - Transfer Case Two/Four Wheel Drive Clutch Retaining Ring 16 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Front 17 - Transfer Case Four Wheel Drive Clutch Housing Retaining Ring 18 - Transfer Case Four Wheel Drive Clutch Housing Page 6118 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 1872 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 14935 Page 14715 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 10814 Page 11685 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 14722 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8480 Page 796 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 17196 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (Except MEX/EXP) Page 9139 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 13205 Fuse Block - I/P Top View Page 15295 Valve Rocker Arm Cover Replacement - Left Side Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side Valve Rocker Arm Cover Replacement - Left Side Removal Procedure 1. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (2). 3. Disconnect the engine harness electrical connector (1) from the ignition coil wire harness. 4. Remove two engine harness clips (4) from the ignition coil bracket studs. 5. Reposition the engine harness, as necessary. 6. Remove the spark plug wires (724) from the ignition coils. * Twist each plug wire 1/2 turn. Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Page 2173 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 5895 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. If equipped with 2 wheel drive (2WD) perform the following steps, if equipped with 4 wheel drive (4WD) proceed to step 5. 3. Remove the connector position assurance (CPA) retainer (2). 4. Disconnect the HO2S electrical connector (3) from the engine wiring harness electrical connector (5). 5. Remove the connector position assurance (CPA) retainer (2). 6. Disconnect the HO2S electrical connector (4) from the engine wiring harness electrical connector (3). Page 446 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 4438 Drive Motor Generator Battery Control Module X4 (HP2) Exhaust - Muffler Heat Shield Buzz During Operation Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust - Muffler Heat Shield Buzz During Operation TECHNICAL Bulletin No.: 07-06-05-001I Date: March 22, 2011 Subject: V8 Engines - Muffler Heat Shield Buzz During Vehicle Operation (Perform Repair as Outlined) or Exhaust Pinging/Popping/Snapping Noise During Cool Down, at Idle, or After Vehicle is Shut Off (Normal Characteristic - No Repair Required) Models: 2007-2011 Cadillac Escalade, Escalade Hybrid, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Tahoe Hybrid 2007-2011 GMC Sierra, Sierra Denali, Yukon, Yukon Hybrid, Yukon XL, Yukon Denali, Yukon Denali XL Equipped with the following V8 Engines: - 4.8L (RPO LY2, L20) - 5.3L (RPOs LC9, LH6, LMG, LY5) - 6.0L (RPOs LFA, LY6, LZ1, L96) - 6.2L (RPOs L9H, L92, L94) Please Refer to GWM/IVH Supercede: This bulletin is being revised to update the Condition, Cause and Correction information. Please discard Corporate Bulletin Number 07-06-05-001H (Section 06 Engine/Propulsion System). Condition 1 Some customers may comment on a pinging/popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing. Cause 1 Exhaust Pinging/Popping/Snapping As the exhaust system cools, the muffler shell and muffler internals contract at different rates. Pinging/popping/snapping noise from the exhaust system during cool down is a normal condition. Correction 1 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Exhaust Pinging/Popping/Snapping Noise (Normal) This condition is normal to the muffler design and does not indicate poor quality or part failure. No repairs are necessary for this condition. Replacing the muffler heat shield straps will NOT eliminate this noise. A new muffler may sound quiet for this condition, but as it ages may again produce this same condition. Condition 2 Some customers may also comment on a buzz noise coming from the muffler during vehicle operation. Cause 2 Muffler Heat Shield Buzz If the muffler heat shield straps are loose, the heat shield may be free to buzz during vehicle operation. Correction 2 DO NOT REPLACE THE EXHAUST SYSTEM COMPONENTS. Muffler Heat Shield Buzz (Perform Repair) Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 12283 Switch Position Icons Page 14755 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 14252 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Fuse Block: Service and Repair 175 Amp Mega Fuse Replacement (With Auxiliary Battery) 175 Amp Mega Fuse Replacement (With Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 10562 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Page 1063 Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Motor (A48) Body - Tailgate Handle/Latch Binds/Hard To Open Tailgate Latch: Customer Interest Body - Tailgate Handle/Latch Binds/Hard To Open TECHNICAL Bulletin No.: 09-08-66-009A Date: May 25, 2010 Subject: Intermittent Pickup Box Endgate Latch Binding, Hard to Open, Does Not Open (Re-Work Endgate Latch Rods) Models: 2009 Chevrolet Silverado 2009 GMC Sierra Supercede: This bulletin is being revised to remove the endgate latch handle re-work. Please discard Corporate Bulletin Number 09-08-66-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the endgate is binding, is hard to open or does not open at all. Applying excessive upward force to the endgate latch handle may allow the endgate to open as designed. Cause This condition may be caused by a fitment concern with the endgate latch rods in the endgate assembly. Correction Re-work the right endgate right latch rod to increase the handle travel. Follow the re-work procedure below. 1. Remove the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. 2. Remove the right endgate latch. Refer to Endgate Latch Replacement in SI. 3. Remove the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 4. Remove the foam (1) from the latch rod. 5. Measure the overall length of the rod. Note the measurement. The following steps will instruct how to reduce the overall length of the rod by 3-4 mm (0.118-0.157 in). Page 326 Page 9315 26 - Front Differential Case 27 - Differential Pinion Gear Shaft Lock Bolt 28 - Differential Side Bearing 29 - Differential Side Bearing Cup 30 - Front Differential Ring Gear 31 - Front Differential Half Carrier Location Pin 32 - Front Differential Bearing Adjuster Nut Lock 33 - Differential Pinion Gear 34 - Differential Pinion Gear Thrust Washer 35 - Differential Side Gear Thrust Washer 36 Differential Side Gear 37 - Differential Pinion Gear 38 - Differential Pinion Gear Thrust Washer 39 Front Differential Side Gear Spacer 40 - Front Differential Side Gear 41 - Front Differential Side Gear Thrust Washer 42 - Front Differential Drive Pinion Gear 43 - Differential Drive Pinion Gear Bearing Shim 44 - Front Differential Drive Pinion Gear Inner Bearing 45 - Front Differential Drive Pinion Gear Inner Bearing Cup 46 - Front Differential Drive Pinion Gear Bearing Spacer 47 - Front Differential Carrier Bushing 48 - Front Differential Carrier 49 - Front Differential Bearing Adjuster Nut Lock 50 - Bolt 51 - Front Differential Drive Pinion Gear Yoke Nut 52 - Front Differential Drive Pinion Gear Thrust Washer 53 - Front Differential Drive Pinion Gear Yoke 54 - Front Differential Drive Pinion Gear Bearing Dirt Deflector 55 - Front Differential Drive Pinion Gear Seal 56 - Front Differential Drive Pinion Gear Outer Bearing Cup 57 - Front Differential Drive Pinion Gear Outer Bearing 58 - Front Differential Carrier Bushing 59 - Differential Bearing 60 - Front Differential Bearing Adjuster O-Ring Seal 61 - Front Differential Bearing Adjuster 62 - Front Drive Axle Inner Shaft Seal 63 - Front Drive Axle Inner Shaft Retaining Ring 64 - Front Drive Axle Inner Shaft 65 Front Differential Carrier Vent 66 - Fuel and Oil Resistant Hose 67 - Clamp 68 - Front Differential Carrier Vent Hose Connector 69 - Front Differential Carrier Oil Drain Plug 70 - Front Differential Carrier Oil Drain Plug Washer 71 - Front Differential Carrier Oil Fill Plug 72 - Front Differential Carrier Oil Fill Plug Washer Page 13337 Page 2675 Page 9159 Input Speed Sensor (ISS) (M30) Page 7831 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 10811 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Page 7008 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 3698 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Side Removal Procedure Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause the pan to be bent against the pump screen. This will result in a damaged oil pickup unit. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. If the vehicle is equipped with four wheel drive (4WD), remove the front drive axle. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD), See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement 3. If the vehicle is equipped with 4WD, remove the front drive axle bracket bolts and bracket. 4. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L, and 6.2L) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (6.6L) (See: Exhaust System/Exhaust Manifold/Service and Repair )Exhaust Manifold Replacement - Right Side (4.3L) (See: Exhaust System/Exhaust Manifold/Service and Repair) . 5. Remove the air conditioning (A/C) compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement (Non-HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair)Air Conditioning Compressor Bracket Replacement (HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair) . 6. Remove the engine mount to frame bolts (1). Page 3097 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Page 11819 Page 10741 5. Install the BPMV bolts (1) and tighten to 9 Nm (80 lb in) . 6. Position the hydraulic control unit and bracket assembly (1) to the frame rail. Slide the assembly toward the left of the vehicle and install the assembly to the vehicle frame. Page 4505 1. Position the ground strap (2) to the drive motor generator control module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ground strap bolt (1) and tighten to 9 Nm (80 lb in) . 3. Install the air cleaner assembly. Refer to Upper Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 17444 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 11108 5. Assemble 4 new O-ring seals to the supply and return transfer tubes (1). 6. Lubricate the new O-ring seals with GM approved brake fluid from a clean, sealed brake fluid container. 7. Install the supply and return transfer tube assemblies to the brake modulator valve assembly. 8. Install the brake pipe manifold (1). Page 9056 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 12096 Center Instrument Panel Fuse Block CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 12878 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement 1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest diameter of the brake drum at 4 or more points, equally spaced around the drum. Ensure that the measurements are only taken within the brake shoe lining contact area and that the micrometer is positioned the same distance from the outside edge of the drum for each measurement. 3. The maximum allowable diameter : Maximum allowable measurement 296.5 mm (11.673 in) 4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter, the drum may be able to be resurfaced, depending upon surface and wear conditions which may be present. 5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable measurement, the drum requires replacement. Page 4253 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 4983 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Page 10091 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Page 13691 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Top of the I/P Components (CJ2) Page 20662 Page 7034 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 10234 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1704 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4952 Page 19554 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8282 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 11936 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 6258 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 15070 Page 17903 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Extended Cab) Rear Side Door Sill Trim Plate Replacement (Extended Cab) Page 12278 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 10421 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 18233 Memory Seat Module (MSM) X5 (AN3) Page 12732 X215 Inline Harness Connector End Views X215 Body Harness to I/P Harness (HP2) Page 14767 Disclaimer Page 19441 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 5758 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Drivetrain - Whine or Click Type Noises from Front Axle Carrier Bearings: All Technical Service Bulletins Drivetrain - Whine or Click Type Noises from Front Axle TECHNICAL Bulletin No.: 09-04-19-001 Date: April 28, 2009 Subject: Whine or Click Type Noises from Front Axle/New Design Front Axle Side Bearing Adjusters (Inspect/Replace with New Lock Rings) Models: 2002-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2002-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2002-2009 GMC Sierra, Yukon, Yukon XL All Equipped with 8.25" Front Axle Condition Some customers may comment about whine or click type noises from the front axle. Upon further investigation, disassembly of the front differential may reveal chipped pinion or ring gear teeth. Cause This condition may be caused by an oversize front bearing side adjuster lock ring allowing the adjuster to move. New Design Lock Adjusters Vs Old Design T-Lock Adjusters Note Front axle housings for old-style (Classic - GMT800) and new-style (GMT900) vehicles are not interchangeable. The new design eliminates the side bearing adjusters movement. The lock adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. All front axle housings for all model years will use the new design adjusters, and use the new lock ring. The t-lock adjusters are still available, but if a housing replacement is needed, it is necessary to order the lock ring style housing, two of the new adjusters and two of the lock rings. Part numbers are available through the GM Parts catalog. A newly designed 8.25" front axle is in production. The new design eliminates the t-lock side bearing adjusters. The new adjusters are retained by a pressed in lock ring that maintains the adjuster setting for backlash and side bearing preload. This design was phased into production during September, 2006. As a result, in the 2007 model year, both old-style (Classic - GMT800) and new-style (GMT900) vehicles built before the change have the t-lock design adjusters, and both types of vehicles built after the change have the lock ring design adjusters. Correction If no damage is visible and the concern was a whine or click noise, follow the inspect procedure in this bulletin and replace the lock ring. Complete assembly replacement is not necessary if an oversized slipping lock ring was found. Important The bearing adjuster lock rings are not reusable. Inspect New Replacement Part Prior to Installation Page 7358 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 14317 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 18579 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10209 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Torque Converter: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 11595 Positive: Service and Repair Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Removal Procedure 1. Disable the high voltage system. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the auxiliary bussed electrical center (BEC) cover (1). 3. Remove the positive battery cable nut (1) from the mega fuse stud. 4. Remove the positive battery cable lead (5) from the mega fuse stud. 5. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 6. Remove the positive battery cable clips (2, 3, and 4) from the frame crossmember. Page 437 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 3668 Service and Repair Structural Brace: Service and Repair Front End Sheet Metal Diagonal Brace Replacement Page 19473 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Page 13342 Junction Block - Left I/P X1 (except MEX) Page 7731 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 62 Disclaimer Page 9102 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 18523 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 Page 552 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Page 12120 Junction Block - Right I/P (Wire Entry) Locations Audible Warning Device Control Module: Locations Instrument Panel/Center Console Component Views Inside the I/P Components (UL5) 1 - Chime Module Page 10475 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case High/Low Shift Fork Pad 11 - Transfer Case High/Low Shift Fork 12 - Transfer Case High/Low Shift Fork Spring Assembly 13 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 14 - Transfer Case Two/Four Wheel Drive Actuator Cam Spacer 15 - Transfer Case Two/Four Wheel Drive Actuator Cam 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case High/Low Shift Fork Pin 18 - Transfer Case Actuator Shaft Gear 19 - Transfer Case Rear Output Shaft Assembly 20 - Transfer Case Front Output Shaft Drive Chain Assembly 21 - Transfer Case Front Output Shaft Drive Sprocket 22 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly Page 4652 13. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 14. Clean the sealing surface of the PIM cover as necessary. 15. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 16. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . 17. Install the ground strap (2) and bolt (1). Tighten the bolt to 22 Nm (16 lb ft) . Page 17316 occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Page 1049 Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF/NQH) Transfer Case Shift Control Module X2 (NQF/NQH) Page 12145 Page 3644 13. Install the surge tank outlet hose (2) to the heater hose bracket (3). 14. Install the heater inlet hose (2) to the heater hose bracket (3). Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 7726 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Page 13639 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 1662 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 4009 CMP Actuator System Performance Diagnostic The engine control module (ECM) monitors the performance of the camshaft position (CMP) actuator system by monitoring the calibrated desired position and the actual position of the camshaft, through the 4X signal of the CMP sensor. If the difference between the actual and the desired position is greater than a calibrated angle for a calibrated amount of time, DTC P0011 will set. Page 10710 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 10621 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 386 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Page 8259 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2950 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 18531 Page 20823 Page 20591 Door Lock/Window Switch - Driver X7 (AN3/DL3) Page 6015 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 7980 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 5828 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8882 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Page 12394 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 5431 Page 6313 Valve Deactivation Solenoid: Description and Operation Cylinder Deactivation (Active Fuel Management) System Description To provide maximum fuel economy under light load driving conditions, the engine control module (ECM) will command the cylinder deactivation system ON to deactivate engine cylinders 1, 7, 6, and 4, switching to a V4 mode. The engine will operate on 8 cylinders or V8 mode, during engine starting, engine idling, and medium to heavy throttle applications. When cylinder deactivation is commanded, the ECM will determine what cylinder is firing, and begin deactivation on the next closest deactivated cylinder in firing order sequence. For example, if cylinder number 1 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 7. If cylinder number 5 is on its combustion event when cylinder deactivation is commanded ON, the next cylinder in the firing order sequence that can be deactivated is cylinder number 4. Cylinder deactivation is accomplished by not allowing the intake and exhaust valves to open on the selected cylinders by using special valve lifters. The deactivation lifters contain spring loaded locking pins that connect the internal pin housing of the lifter to the outer housing. The pin housing contains the lifter plunger and pushrod seat which interfaces with the pushrod. The outer housing contacts the camshaft lobe through a roller. During V8 mode, when all cylinders are active, the locking pins are pushed outward by spring force, locking the pin housing and outer housing together causing the lifter to function as a normal lifter. When cylinder deactivation is commanded ON, the locking pins are pushed inward with engine oil pressure directed from the valve lifter oil manifold (VLOM) assembly solenoids. When the lifter pin housing is unlocked from the outer housing, the pin housing will remain stationary, while the outer housing will move with the profile of the camshaft lobe, which results in the valve remaining closed. One VLOM solenoid controls both the intake and exhaust valves for each deactivating cylinder. There are 2 distinct oil passages going to each cylinder deactivation lifter bore, one for the hydraulic lash-adjusting feature of the lifter, and one for controlling the locking pins used for cylinder deactivation. Although both intake and exhaust valve lifters are controlled by the same solenoid in the VLOM, the intake and exhaust valves do not become deactivated at the same time. Cylinder deactivation is timed so that the cylinder is on an intake event. During an intake event, the intake CAM lobe is pushing the valve lifter upwards to open the intake valve against the force of the valve spring. The force exerted by the valve spring is acting on the side of the lifter locking pins, preventing them from moving until the intake valve has closed. When the intake valve lifter reaches the base circle of the Page 8937 16. Install the retainer securing the cable to the steering column. 17. Position the carpet and insulation around the driver area. 18. Install the body hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 19. Install the driver seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket) . 20. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 21. Test the transmission for proper shift operation. 22. If all of the gear positions cannot be achieved, adjust the cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments) . Page 20854 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 13562 Junction Block - Left I/P X13 (AN3) Page 11427 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 14947 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2/C67) Page 4603 Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 1197 Door Lock/Window Switch - Passenger X3 (AN3/DL3) Page 12678 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 248 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2767 Fuse Block - Underhood X3 Page 14920 Instrument Panel Center Air Outlet Replacement (With RPO SLT) Instrument Panel Center Air Outlet Replacement (With RPO SLT) Page 14383 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 20012 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 13753 X214 Inline Harness Connector End Views Page 11696 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 8640 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Page 9107 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 19423 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 2781 Fuse Block - Auxiliary X2 (HP2) Page 11597 1. Install the positive battery cable (1) to the vehicle. 2. Connect the positive battery cable electrical connector (1) to the drive motor generator control module. 3. Install the positive battery cable clip (5) to the fender inner panel. 4. Install the positive battery cable clip (4) to the air cleaner support bracket. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 6. Raise and suitably support the vehicle enough to work through the wheel opening. 7. Working through the wheel opening, install the positive battery cable clip (3) to air cleaner adapter bracket 8. Working through the wheel opening, install the positive battery cable clip (2) to the brake pipe. 9. Fully raise the vehicle. Page 3480 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2643 Page 13531 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 2909 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 16044 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Engine - Valve Lifter Tick Noise At Start Up Wiring Harness: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 10273 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 3891 Intake Manifold: Specifications Intake Manifold Bolts - First Pass in Sequence.................................................................................... ............................................................5 Nm (44 lb in) Intake Manifold Bolts - Final Pass in Sequenc e.............................................................................................................................................10 Nm (89 lb in) Intake Manifold Sight Shield Retainer Bolts....................................................................................................................................................5 Nm (44 lb in) Throttle Body Bolts.......................................................................................................... ..............................................................................10 Nm (89 lb in) Throttle Body Nuts....................... .............................................................................................................................................................. ....10 Nm (89 lb in) Throttle Body Studs............................................................................................... ...........................................................................................6 Nm (53 lb in) Page 7953 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11884 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 8845 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 19440 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12439 Junction Block - Left I/P X5 (SPO Alarm) Page 4923 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 13029 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 16434 Playback Operation (X = Supported; - = Not Supported) Page 20651 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 4450 Drive Motor Generator Battery Control Module X2 (HP2) Page 2129 Input Speed Sensor (ISS) (M30) Page 5204 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 12622 X175 Engine Harness to Transmission Internal Harness (M30) Page 10097 ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set Brake Bleeding: Technical Service Bulletins ABS/TCS - Brake/ABS/TCS Lamps ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-05-25-006A Date: March 25, 2009 Subject: Hybrid Two-Mode Red Brake Telltale Illuminates Under High Braking Demand or Heavy Regenerative Braking, ABS Traction Control And/Or StabiliTrak Lights On With DTCs C056D 00, C12F3, C12F4 and C12F6 (Check Brake Pedal Travel and Bleed Brake System) Models: 2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Silverado Hybrid, Tahoe Hybrid 2008-2009 GMC Sierra Hybrid, Yukon Hybrid with Two-Mode Hybrid System (RPO HP2) with Active Apply, Disc/Disc, With VSES, With Regen, 7,700 lb Brake System (RPO J92) Supercede: This bulletin is being revised to add the 2009 Chevrolet Silverado and GMC Sierra Hybrid Truck Models. Please discard Corporate Bulletin Number 08-05-25-006 (Section 05 Brakes). Condition Some customers may comment that a red brake telltale illuminates in stop and go traffic under high braking demand or heavy regenerative braking and the ABS lamp is illuminated followed by a" Service Stability Message" displayed in the Driver Information Center. During diagnosis, the technician may find any or all of the following Electronic Brake Control Module (EBCM) and Electrical Control Module (ECM) diagnostic codes set: - C056D 00 : ECU Hardware Performance - C12F3 : ECU Hardware Performance (ABS Left Isolation Solenoid Valve Performance) - C12F4 : ECU Hardware Performance (ABS Right Rear Isolation Solenoid Valve Performance) - C12F6 : ECU Hardware Performance (ABS Proportioning Valve Solenoid Performance) Cause This condition may be caused by an incomplete brake bleeding procedure, allowing the control module to learn invalid actuator offsets. Correction Warning The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to bleed the brake system. Ensure that the recommended procedures are followed to relieve system pressure, to avoid brake fluid spray. Failure to properly follow procedures to depressurize the system may result in personal injury or damage to the vehicle. Refer to Brake Fluid Irritant Warning and Brake Fluid Effects on Paint and Electrical Components Caution in SI. Note Install a midtronics battery charger or equivalent on the vehicle to maintain the battery voltage. Note The brake corners must be cool to obtain the most accurate measurement. Check the brake pedal travel and perform the automated brake bleed procedure with the Tech 2(R) following the procedure below. 1. Place the transmission in the PARK position. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Page 10777 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Page 2824 Fuse Block - Auxiliary X3 (HP2) Page 3489 1. Install a NEW valve lifter oil filter O-ring seal (4) into the valve lifter oil manifold. 2. Install the NEW valve lifter oil filter (3). 3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the oil pressure sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the oil pressure sensor washer (2) and sensor (1). Tighten the sensor to 35 Nm (26 lb ft). 5. Connect the engine harness electrical connector (1) to the oil pressure sensor. 6. Install the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair) . Page 2258 * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287 . 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 4. Remove the J 37287 andCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal ). 5. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 6. If the fuel system components test normal, refer toSymptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 5634 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 5138 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 8830 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8618 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 10349 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 13302 Fuse Block - I/P X3 Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (With Hydroboost) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair) . 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution () . 4. Disconnect the power steering fluid cooler hose (3) from the steering gear (2). 5. Disconnect the power steering fluid cooler hose (4) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2). 7. Remove the power steering fluid cooler (1) from the vehicle. Installation Procedure Page 8761 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 12017 Page 20533 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 10384 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 2976 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7525 Control Module: Locations Instrument Panel/Center Console Component Views Top of the I/P Components (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Component Locations Power Window Switch: Component Locations Door Component Views Left Rear Door Components (Extended Cab) 1 - Door Frame 2 - Window Switch -Left Rear (ABV) 3 - Speaker -Left Rear 4 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 5 - Window Motor -Left Rear (ABV) Left Rear Door Components (Crew Cab) Page 10114 Page 20237 Page 13695 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 7394 Actuator: Diagrams Component Connector End Views Front Drive Axle Actuator (NQF/NQG/NQH) Page 5802 Serial Data Communication Enable Page 6199 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 7682 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 11766 Charging System: Description and Operation Charging System Description and Operation 12-Volt Battery The following information is for the 12-Volt battery only. For information about charging the high voltage drive motor batteries, refer toJump Assist Description and Operation (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Description and Operation/Jump Assist) . Electrical Power Management (EPM) Overview The electrical power management (EPM) system is designed to monitor and control the charging system and send diagnostic messages to alert the driver of possible problems. This EPM system primarily utilizes existing on-board computer capability to maximize the effectiveness of the charging system, manage the load, improve battery state-of-charge and life, and minimize the system's impact on fuel economy. The EPM system performs 3 functions: * It monitors the battery voltage and estimates the battery condition. * It takes corrective actions by adjusting the regulated voltage. * It performs diagnostics and driver notification. The battery condition is estimated during ignition off and during ignition on. During ignition off the state-of-charge (SOC) of the battery is determined by measuring the open-circuit voltage. The SOC is a function of the acid concentration and the internal resistance of the battery, and is estimated by reading the battery open circuit voltage when the battery has been at rest for several hours. The SOC can be used as a diagnostic tool to tell the customer or the dealer the condition of the battery. Throughout ignition-on, the algorithm continuously estimates SOC based on adjusted net amp hours, battery capacity, initial SOC, and temperature. While running, the battery degree of discharge is primarily determined by a battery current sensor, which is integrated to obtain net amp hours. In addition, the EPM function is designed to perform regulated voltage control (RVC) to improve battery SOC, battery life, and fuel economy. This is accomplished by using knowledge of the battery SOC and temperature to set the charging voltage to an optimum battery voltage level for recharging without detriment to battery life. Charging System Components Drive Motor/Generators The drive motor/generators are serviceable components located within the transmission housing. When the rotors are spun, an alternating current (AC) is induced into the stator windings. This AC voltage is then sent to the drive motor generator power inverter module (PIM) where it is converted to high voltage direct current (DC) power. The output of the PIM is converted into low voltage electrical power by the accessory DC power converter module (APM) for use by the vehicle's electrical system to maintain electrical loads and battery charge. Body Control Module (BCM) The body control module (BCM) is a GMLAN device. It communicates with the engine control module (ECM) and the instrument panel cluster (IPC) for electrical power management (EPM) operation. The BCM determines the desired voltage set point and sends the information to the APM. The BCM monitors a battery current sensor, the battery positive voltage circuit, and estimated battery temperature to determine battery state of charge (SOC). Battery Current Sensor The battery current sensor is a serviceable component that is connected to the negative battery cable at the battery. The battery current sensor is a 3-wire hall effect current sensor. The battery current sensor monitors the battery current. It directly inputs to the BCM. It creates a 5-volt pulse width modulation (PWM) signal of 128 Hz with a duty cycle of 0-100 percent. Normal duty cycle is between 5-95 percent. Between 0-5 percent and 95-100 percent are for diagnostic purposes. Engine Control Module (ECM) The ECM receives control decisions based on messages from the BCM. Instrument Panel Cluster (IPC) The IPC provides a means of customer notification in case of a failure and a voltmeter. There are 2 means of notification, a charge indicator and a driver information center (DIC) message of SERVICE BATTERY CHARGING SYSTEM. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 10926 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 15377 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) Page 19031 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 10971 16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange. Page 10426 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11257 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 19694 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 1636 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 11745 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2082 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 11359 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 9335 Carrier Bearings: Service and Repair Differential Side Bearings Replacement Special Tools * J 8092 - Universal Driver Handle - 3/4 in - 10 * J 8107-4 - Side Bearing Remover Plug * J 8107-5 - Side Bearing Remover Plug * J 21784 - Side Bearing Installer * J 22888-D - Side Bearing Puller Set * J 22888-20 A - Side Bearing Puller * J 29710 - Differential Side Bearing Installer * J 36597 - Side Bearing Remover Pilot * J 44420 - Differential Bearing Installer Removal Procedure 1. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 2. Install the 8.6, 9.5, and the 11.5 inch differential assembly into a vise. Note Place a block of wood on each side of the differential assembly 3. Install the 10.5 inch differential assembly into a vise. Note Step 8 is for the 8.6 inch axle. 4. Using the J 22888-20 A - puller (2) and the J 8107-4 - plug (1) , remove the differential side bearing. Note Step 9 is for the 9.5/10.5 inch axles. 5. Using the J 22888-20 A - puller (2) and the J 36597 - pilot (1), remove the differential side bearing. Note Step 9 is for the 11.5 inch axle. 6. Using the J 22888-20 A - puller (2) and the J 8107-5 - plug (1), remove the differential side bearing. Installation Procedure Note Page 20920 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 1490 Battery Current Sensor: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 12090 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 20478 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 9783 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 17936 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Page 9929 Clutch Components 1 - Transfer Case Rear Output Shaft 2 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 3 - Transfer Case Control Lever 4 - Transfer Case Control Actuator Lever Bearing Assembly 5 - Transfer Case Control Actuator Lever Ball (Qty: 3) 6 - Transfer Case Control Actuator Lever Assembly 7 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 8 - Transfer Case Control Actuator Lever Washer 9 - Transfer Case Four Wheel Drive Clutch Pressure - Apply Plate Page 18256 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 13792 Multiple Junction Connector: Diagrams X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 3700 10. Remove the engine mount. Installation Procedure 1. Position the engine mount to the engine. Page 20835 Page 595 Page 18316 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair) . 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair) . Page 13061 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 9075 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13570 Page 10932 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 13247 Fuse 39 ................................................................................................................................................ ..................................... Climate Controls (Battery) Fuse 40 ............................................................... ........................................................................................................................ Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Fuse 71 ................................. .............................................................................................................................................................. ................. Not Used Fuse 72 .............................................................................................................. ............................................................... Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Page 13457 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 13488 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 8124 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 18691 For vehicles repaired under warranty, use the table. Disclaimer Page 2010 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Page 18908 For vehicles repaired under warranty, use the table. Disclaimer Page 1457 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Page 6327 4. Place a straight edge across the front face of the engine block and inspect for proper installation of the CMP actuator and timing chain. With the CMP actuator properly and completely installed onto the front of the camshaft, the timing chain will not protrude beyond the front face of the engine block. 5. Install a NEW CMP actuator solenoid valve (234). With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Page 2195 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 1318 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Page 15846 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 9514 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 16. Secure the small boot clamp (1) usingJ 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 789 Page 19282 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Page 13864 Page 14857 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1585 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 17515 Rear Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Removal Procedure Note If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Page 12733 X278 Inline Harness Connector End Views X278 Instrument Panel harness to Body harness (MEX/A52) Page 12403 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 11655 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 1643 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 16232 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 11266 7. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 8. Disconnect the park brake cable eye (2) from the park brake actuator lever. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Connect the left park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Page 925 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15426 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 4255 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . Page 19620 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 18223 Page 15233 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Front of Vehicle Components (10 Series) Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 6999 10. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 11. Position the generator control module 3 phase cables to the bracket channel. 12. Install the generator control module 3 phase cable clip to the tab (3) on the engine bracket (2). 13. Install the generator control module 3 phase cable clip nut (1). Tighten the nut to 9 Nm (80 lb in). 14. Install the drive motor generator power inverter module cover (2). 15. Tighten the drive motor generator power inverter module cover bolt (1). Tighten the bolt to 1.5 Nm (13 lb in). 16. Connect the engine wiring harness electrical connector (3) to the drive motor generator power inverter module cover. 17. Install the intake manifold sight shield, as required. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 12656 Page 2973 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 18885 Heated/Cooled Seats Inoperative In warmer or cooler climates where room temperature conditions of 70°F (21°C) may be unattainable, resistance values may read above the specified range. Use a heat gun or a blower to warm or cool the TED while measuring the resistance. The resistance values should slowly lower toward the specified range. 5. Test for 0.9 - 10.0 Ω between the control circuits listed below: * Seat cushion control circuit terminal A X1 and control circuit terminal B X1 * Seat back control circuit terminal C X1 and control circuit terminal D X1 ‹› If less than the specified range, test for a short between the appropriate control circuits. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. ‹› If greater than the specified range, test the appropriate control circuits for an open/high resistance. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. 6. Connect the X1, X2, X3 harness connectors at the CCSM. 7. Disconnect the harness connector at the seat cushion heat/cool seat ventilation blower. 8. Test for less than 5 Ω between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 9. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 10. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 11. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat cushion blower motor control terminal 2 * Seat cushion blower motor speed control terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 12. Ignition OFF, connect the harness connector to the seat cushion heat/cool seat ventilation blower. 13. Disconnect the harness connector at the seat back heat/cool seat ventilation blower. 14. Test for less than 5 Ω between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 15. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. Page 3287 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 4264 Water Pump: Diagrams Component Connector End Views Generator Control Module Coolant Pump - Left (HP2) Generator Control Module Coolant Pump - Right (HP2) Page 10233 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 13381 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chassis Harness Routing (LY6/LMM except 31 Series) Page 7108 Page 1080 Page 16100 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 16872 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 12946 Page 10366 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 12131 Fuse 39 ................................................................................................................................................ ..................................... Climate Controls (Battery) Fuse 40 ............................................................... ........................................................................................................................ Airbag System (Ignition) Fuse 41 ................................................................................................................................. .............................................................................. Amplifier Fuse 42 .................................................. ....................................................................................................................................................... Audio System Fuse 43 ........................................................................................................................ ....................................... Miscellaneous (Ignition), Cruise Control Fuse 44 ........................................ .............................................................................................................................................................. .......... Not Used Fuse 45 ..................................................................................................................... ................................................................... Airbag System (Battery) Fuse 46 .................................... .................................................................................................................................................... Instrument Panel Cluster Fuse 47 ....................................................................................................... .............................................................................................. Power Take-Off Fuse 48 ...................... ............................................................................................................................................... Auxiliary Climate Control (Ignition) Fuse 49 ........................................................................................................................................................... Center High-Mounted Stoplamp (CHMSL) Fuse 50 ............................................................................ ............................................................................................................................ Rear Defogger Fuse 51 ......................................................................................................................................................... .............................................. Heated Mirrors Fuse 52 ........................................................................ .................................................................................................. SEO B1 Upfitter Usage (Battery) Fuse 53 ............................................................................................................................................................. Cigarette Lighter, Auxiliary Power Outlet Fuse 54 ............................................................................... ................................................................................................................ SEO Upfitter Usage Fuse 55 ......................................................................................................................................................... ........................... Climate Controls (Ignition) Fuse 56 .................................................................................................................................... Engine Control Module, Secondary Fuel Pump (Ignition) J-CASE FUSES ................................................................................................................................... ................................................................... USAGE Fuse 57 ................................................................................................................................................ ........................................................ Cooling Fan 1 Fuse 58 ............................................................... ................................................................................................................................................. Not Used Fuse 59 ...................................................................................................................................... ................................ Heavy Duty Antilock Brake System Fuse 60 ...................................................... .................................................................................................................................................. Cooling Fan 2 Fuse 61 ........................................................................................................................ ............................................................... Antilock Brake System 1 Fuse 62 ........................................ .............................................................................................................................................................. .............. Starter Fuse 63 ..................................................................................................................... ..................................................................... Stud 2 (Trailer Brakes) Fuse 64 .................................... ......................................................................................................................................... Left Bussed Electrical Center 1 Fuse 65 ................................................................................................................. ............................................................................................... Not Used Fuse 66 ................................ ....................................................................................................................................... Heated Windshield Washer System Fuse 67 ................................................................................................... ...................................................................................................... Transfer Case Fuse 68 ........................................................................................................ Stud 1 (Trailer Connector Battery Power) (Optional - 40A Fuse Required) Fuse 69 .................................................. ........................................................................................................................... Mid-Bussed Electrical Center 1 Fuse 70 ................................................................................................................. ........................................................................ Climate Control Blower Fuse 71 ................................. .............................................................................................................................................................. ................. Not Used Fuse 72 .............................................................................................................. ............................................................... Left Bussed Electrical Center 2 RELAYS .............................................................................................................................................. .................................................................... USAGE FAN HI ................................................................................................................................................. ...................................... Cooling Fan High Speed FAN LO ................................................................ ....................................................................................................................... Cooling Fan Low Speed FAN CNTRL ............................................................................................................................. ........................................................ Cooling Fan Control HDLP LO/HID ............................................ .................................................................................................................................... Low-Beam Headlamp FOG LAMP ......................................................................................................................... ................................................................... Front Fog Lamps A/C CMPRSR ...................................... ............................................................................................................................... Air Conditioning Compressor STRTR ............................................................................................................................ ........................................................................................ Starter PWR/TRN ....................................... .............................................................................................................................................................. ... Powertrain FUEL PMP .................................................................................................................... ................................................................................... Fuel Pump PRK LAMP .................................... ............................................................................................................................................................ Parking Lamps REAR DEFOG ............................................................................................................ ............................................................................... Rear Defogger RUN/CRANK ............................... .......................................................................................................................................................... Switched Power Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Page 6604 For vehicles repaired under warranty, use the table above. Disclaimer Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 14359 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 4901 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 2782 Fuse Block - Auxiliary X3 (HP2) Page 2317 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 8151 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 498 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 16067 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Page 9775 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Voice Recognition System - Won't Recognize Bluetooth(R) Steering Mounted Controls Communication Module: Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 13210 Fuse Block - I/P X4 Page 15697 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 Page 10198 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 9855 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 7821 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 7168 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 1157 Remote Switch: Locations Instrument Panel/Center Console Component Views Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 2798 Page 14650 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair) . Page 16845 Disclaimer Page 14748 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6304 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Locations Towing Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 20632 Sliding Rear Window Open Relay (A48) Sliding Rear Window Switch (A48) Page 10650 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 4151 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 15284 HVAC Control Module X2 (CJ2) Page 8325 Page 4970 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 4806 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Page 12140 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 15593 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended/Crew Cab with ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Page 4508 Caution: To avoid high voltage 3-phase cable or vehicle damage properly attach the cables and brackets, and check for and correct any interference. 1. Position the 3 phase cables in the vehicle. 2. Begin installation of the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . 3. Install a new 3 phase cable housing seal (2). 4. Install the 3 phase cables and housing (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Install the 3 phase cable retaining bolts (4). Tighten the bolts to 12 Nm (106 lb in). 6. Install the 3 phase cable bolt protective cover (5). 7. Install a new 3 phase cable cover seal (6). 8. Reconnect the 3 phase cable cover connector. 9. Install the 3 phase cable cover (7). 10. Install the transmission cover terminal housing (8). 11. Install the 3 phase cable cover bolts (9). Tighten the bolts to 12 Nm (106 lb in). 12. Install the 3 phase cable bracket bolts (1). Tighten the bolts to 12 Nm (106 lb in). 13. Complete installation of the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement) . 14. Lower the vehicle. Page 7380 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 16863 Page 4584 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Page 12150 Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 17232 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Body Control Module (BCM) X2 Page 7336 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 768 Page 2659 Fuse Block - I/P X4 Page 10633 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Page 10566 Page 3204 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 2509 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Page 10129 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Selector Switch - O-Ring - Seal 7 - Transfer Case Shift Control Switch Assembly 8 - Transfer Case Front Half 9 - Transfer Case Half Locating Pin 9 - Transfer Case Half Locating Pin 10 - Transfer Case Input Shaft Bearing Assembly 11 - Transfer Case Input Shaft Inner Retaining Ring 12 - Transfer Case High/Low Internal Gear 13 - Transfer Case High/Low Internal Gear Retaining Ring 14 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 15 - Vehicle Speed Sensor Assembly 16 - Vehicle Speed Sensor O-Ring - Seal 17 - Transfer Case Rear Half 18 - Transfer Case Access Hole Plug 19 - Transfer Case - Harness - Bracket 20 - Transfer Case Half Bolt/Screw (Qty: 17) 21 - Transfer Case Rear Output Shaft Bushing 22 - Transfer Case Rear Output Shaft Seal 23 - Transfer Case Oil Fill Plug 24 - Transfer Case Oil Drain Plug 25 - Transfer Case Front Output Shaft Rear Bearing Assembly 26 - Transfer Case Shift Detent Plunger Plug 27 - Transfer Case Shift Detent Plunger Plug O-Ring - Seal 28 - Transfer Case Shift Detent Spring 29 - Transfer Case Shift Detent Plunger 30 Transfer Case Shift Detent Lever Bearing Assembly 31 - Transfer Case Shift Lever Seal 32 Transfer Case Shift Lever 33 - Transfer Case Control Lever Bolt/Screw 34 - Transfer Case Shift Lever - Rubber - Seal Internal Components Page 6902 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. Page 10307 Page 8857 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 12760 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 12206 Fuse Block - Underhood X4 Page 5411 Body Control Module (BCM) X5 Page 10237 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. OnStar(R) - Aftermarket Device Interference Information Global Positioning System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 9246 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Page 8751 Page 2302 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the spark plug. Tighten the plug to 15 Nm (11 lb ft). Page 18411 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 12621 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Page 19574 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 13551 Junction Block - Left I/P X2 (except MEX) Page 18333 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Housing Drain Gutter Replacement (Extended Cab) Sunroof Housing Drain Gutter Replacement (Extended Cab) Removal Procedure Note Tape off the perimeter of the sunroof window opening before removing the sunroof module to prevent scratching. 1. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair )Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair) . 2. Set the sunroof window to be in the open position of a minimum of 25 mm (1 in). Note It is only necessary to lower the headlinder. Only do those steps in headlinder replacement that will lower the headlinder enough to grain access. 3. Remove the sunroof module assembly. 4. Remove the screws (1) from the water gutter (2). Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Page 15247 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Front of Vehicle Components (10 Series) Page 2279 Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Locations Drive Motor Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 2067 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 13519 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1797 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Page 2761 Fuse Block - Underhood Bottom View Page 19667 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Service and Repair Radiator: Service and Repair Radiator Air Upper Baffle and Deflector Replacement Removal Procedure 1. Remove the radiator air upper baffle retainers (Qty 8). 2. Remove the radiator air upper baffle. Installation Procedure 1. Install the radiator air upper baffle. 2. Install the radiator air upper baffle retainers (Qty 8). Page 4955 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Page 13230 Junction Block - Left I/P X10 (except MEX) Page 2835 Junction Block - Left I/P X2 (except MEX) Page 4612 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 9908 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 16815 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 2298 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 5625 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 2827 Page 10936 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing) . * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe) . If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Page 12933 Module Circuit Function Icons Voice Recognition System - Won't Recognize Bluetooth(R) Steering Mounted Controls Communication Module: Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 10921 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 7205 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12512 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 7. Install the fuse cover. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Page 1347 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 13078 Branching Point: Diagrams JX223 Splice Pack Connector End Views JX223 (U2K/UK6/UE1 without Y91) Page 11548 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Endgate Emblem/Nameplate Replacement (Silverado) Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Page 19755 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 13779 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) Page 12102 Junction Block - Left I/P, Bottom View Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 11140 1. Install the 3 master cylinder reservoir seals (1). Lubricate the master cylinder reservoir seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the master cylinder reservoir (1) to the master cylinder. Ensure the master cylinder reservoir is seated fully into the master cylinder by pressing the reservoir straight down into the master cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Component Locations Auxiliary Battery Relay: Component Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 3905 18. Install the intake manifold (500). 19. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads of the intake manifold bolts (512). Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Note The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 20. Install the intake manifold bolts (512) finger tight. 21. Tighten the intake manifold bolts to specifications. * Tighten the bolts a first pass in the sequence shown to 5 Nm (44 lb in). * Tighten the bolts a final pass in the sequence shown to 10 Nm (89 lb in). Page 20679 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 11138 5. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside. 6. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside. 7. Remove the brake master cylinder reservoir pins (1). Page 12870 2. Obtain a revised wiring harness clip (Warranty Parts Center (WPC) # 577) from the WPC. Refer to Parts Information below. 3. Insert the motor harness (minus the two separate brown wires) into the revised wiring harness clip. 4. Position the two brown wires into the access slot (1) located on the internal side of the wiring harness clip. 5. Engage the locking tab (1) to retain the harness within the clip. 6. Install the wiring harness clip back into the motor housing. The drive motor is now ready to be installed into the transmission case. Parts Information To obtain the revised wiring harness clip, fax the form included in this bulletin to the GM Warranty Parts Center (WPC). Request WPC#577 for the wiring harness clip. Page 10402 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 6325 1. Compress the timing chain tensioner guide and install the EN 46330 . Note * Properly locate the CMP actuator on the locating pin of the camshaft. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. * DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly. 2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Page 2502 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500 HD, and 3500 HD SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Specifications Firing Order: Specifications Ignition System Specifications Page 17082 Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Steering Wheel Components Page 20480 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 6675 5. Pull the fuel line connection apart. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male connection end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Connect Procedure Warning In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the fitting together in order to engage the retaining tabs. Page 13418 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 16769 In an effort to maintain the highest customer satisfaction level, dealers are being urged to obtain the necessary information from the customer (name, VIN, odometer reading) to pre-order a replacement OnStar(R) module, allowing for a single repair visit. Dealer technicians should replace the OnStar(R) VCIM per the applicable procedure outlined in the vehicle specific Service Information. Refer to Communication Interface Module Replacement in SI. Make sure to perform the applicable module set-up and activation procedures. Refer to Communication Interface Module Programming and Setup in SI. Parts Information Important FOR INVOLVED VEHICLES REQUIRING A REPLACEMENT UNIT, DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO) OR THE TECHNICAL ASSISTANCE CENTER (TAC).ONLY VEHICLES OF CUSTOMERS RECEIVING A NOTICE REGARDING THIS CONDITION ARE APPLICABLE TO THIS SPECIAL PART ORDERING PROCESS.ORDERS BEING PLACED FOR VEHICLES NOT INVOLVED IN THIS CUSTOMER NOTIFICATION PROCESS WILL BE REFERRED TO GM TECHNICAL ASSISTANCE. US: OnStar(R) modules required for this procedure are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com and selecting the catalog item that contains this bulletin number or by calling 1-800-336-3998. The dealer must provide the VIN, Repair Order (R.O.) number and the current vehicle odometer reading. Note When ordering online, use the "OnStar Gen 8.0c No Connect" selection located on the Place Order page. Canada: OnStar(R) modules required for this procedure are to be obtained by contacting MASS Electronics at 1-877-410-6277. The dealer must provide the VIN, R.O. number and the current odometer reading. Warranty Information For vehicles repaired under warranty, use the applicable model-specific labor time. Disclaimer Sample Owner Letter Sample Customer Notification Letter Dear OnStar(R) Subscriber Our records indicate that the OnStar(R)1 system in your vehicle may not be functioning properly. This situation could affect your vehicle's battery performance. In order to avoid any inconvenience to you or loss of OnStar(R) safety and security services, we recommend that you immediately: - Press your blue OnStar(R) button. - If you connect to a live OnStar(R) advisor, then there is no need for any further action. - If your blue button does not connect to an OnStar(R) advisor, try the red emergency button (inform the Advisor that you don't have an emergency, but need OnStar(R) Technical Assistance). - If you can't connect to OnStar(R) through either button, please see your dealer; there may be a problem with the OnStar(R) system in your vehicle. Simply contact any GM Dealership to schedule an appointment for a no-cost repair. Please have your VIN, mileage, and the Bulletin Number noted below. By calling in advance, your dealer can have the replacement part ready when you drop-off your vehicle. - VIN: xxxxxxxxx80202480 - Bulletin No.: 09-08-46-004 If you have any questions regarding this service, please call us at 1.888.4.ONSTAR (1.888.466.7827) and press "9" for Technical Assistance. Simply Page 7839 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6690 Page 19716 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 3665 Page 13209 Fuse Block - I/P X3 Page 20024 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 2240 If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4435 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 7574 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Page 131 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4676 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 5. Remove the drive motor generator power inverter control module (PIM) 3 phase cable terminal fasteners (1). Caution: High Voltage (HV) cables should never be removed from the mounting block. Removal of the individual HV cable from the mounting block may result in HV cable and/or component damage from improper: * Cable sealing * Electrical shielding * Terminal position assurance 6. Remove the PIM 3 phase cable mounting fasteners (2, 4). 7. Remove the PIM 3 phase cables (3, 5) from the PIM distribution box. 8. Remove and discard the seals (6). Page 11368 4. Tighten the trailer brake control module bolts (1) to 9 Nm (80 lb in) . 5. Connect the trailer brake control module electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 7. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 10922 WARRANTY INFORMATION Page 587 Page 10495 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 18787 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 17134 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Specifications Refrigerant Oil: Specifications Refrigerant Oil Type Polyolester (POE) Oil GM P/N 88862657 (GM P/N 88862658 Canada) Page 2886 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Page 5596 Page 12135 Junction Block - Rear Lamps X4 Page 20270 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 227 Parking Assist Control Module: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 13186 Page 20661 Window Switch - Right Rear (Crew Cab with A31/Extended Cab with ABV) Page 19841 Page 12951 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 3828 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the oil filter adapter (438). Tighten the adapter to 55 Nm (40 lb ft). 2. Lubricate the oil filter seal with clean engine oil. 3. Install the oil filter (437). Tighten the filter to 30 Nm (22 lb ft). Page 13828 X176 Engine Harness to Transmission Harness (M99) X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 18836 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 5705 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 4647 Drive Motor Control Module: Service and Repair Accessory DC Power Control Module Removal and Installation Accessory DC Power Control Module Removal and Installation Special Tools * J 24460-01 - Cooling System Pressure Tester * GE-48494 - Power Electronics Pressure Test Adapter Kit Removal Procedure 1. Remove the drive motor generator control module from the vehicle. Refer to Drive Motor Generator Control Module Assembly Replacement ( See: Drive Motor Generator Control Module Assembly Replacement) . 2. Remove the APM ground strap bolt (1) and ground strap (2). Page 14834 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Page 1016 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Page 10250 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2019 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series Except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series Except Crew Cab/MEX) Page 4708 Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Page 11325 Hydraulic Fluid Accumulator: Removal and Replacement Hydraulic Brake Booster Accumulator Replacement Hydraulic Brake System Bleeding (Two-mode Hybrid) Special Tools * J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent * J-35589-A - Brake Pressure Bleeder Adapter, or equivalent Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: When adding fluid to the brake master cylinder reservoir, use only GM approved or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place the transmission in the PARK position. 2. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. 3. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6. Visually inspect the brake system for brake fluid leaks and damage. Refer to Symptoms Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Repair or replace components as necessary. 7. Lower the vehicle to a working height to bleed the hydraulic brake system. 8. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or from the brake pressure modulator valve (BPMV), you must perform the following steps to bleed air at the ports of the hydraulic brake component: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. Clean the outside of the master cylinder reservoir on and around the cap prior to removal. 3. With the brake pipes installed securely to the affected hydraulic brake system component, loosen and separate one of the brake pipes from the port of the affected hydraulic brake system component. 4. Allow a small amount of brake fluid to gravity bleed from the open port of the affected hydraulic brake system component. 5. Reconnect the brake pipe to the affected hydraulic brake system component port and tighten securely. 6. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 7. Loosen the same brake pipe to purge air from the open port of the affected hydraulic brake system component. 8. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 8.3-8.8 until all air is purged from the same port of the affected hydraulic brake system component. 10. With the brake pipe installed securely to the affected hydraulic brake system component, after all air has been purged from the first port of the affected hydraulic brake system component that was bled, loosen and separate the next brake pipe from the affected hydraulic brake system component, then repeat steps 8.3-8.8. 11. After completing the final affected hydraulic brake system component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 9. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 10. Install the J-35589-A - Brake Pressure Bleeder Adapter, or equivalent , to the brake master cylinder reservoir. 11. Inspect the brake fluid level in the J-29532-A - Brake Pressure Bleeder , orJ-29532 - Diaphragm Pressure Bleeder , or equivalent. 12. Clean the outside of the J-29532-A or the J 29532 and add GM approved, or equivalent, brake fluid from a clean sealed brake fluid container, as necessary. Page 15112 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 8488 Do not tighten the bolts at this time. 4. Install by hand the control valve body bolts (3) to the control solenoid valve and TCM assembly. 5. Install the wire harness retainer (2). Note Do not tighten the bolts at this time. 6. Install by hand the control solenoid valve heat sink bolts (1) to the control solenoid valve and TCM assembly. Caution: Bolt torque sequencing is critical to the proper function of the control solenoid valve assembly. Failure to follow the required sequencing may result in transmission malfunction. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Torque the bolts following the specified sequence. Tighten the control valve body bolts to 11 Nm (97 lb in). Tighten the control solenoid valve heat sink bolts to 7 Nm (62 lb in). Page 8020 10 - Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4) 11 - Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plate (Qty: 7) 12 - Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plate (Qty: 8) 13 - Transfer Case Four Wheel Drive Clutch Hub 14 Transfer Case Four Wheel Drive Clutch Shim 15 - Transfer Case Two/Four Wheel Drive Clutch Retaining Ring 16 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Front 17 - Transfer Case Four Wheel Drive Clutch Housing Retaining Ring 18 - Transfer Case Four Wheel Drive Clutch Housing Brakes - Front Brake Induced Pulsation/Vibration Brake Pad: All Technical Service Bulletins Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Page 11531 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 20241 Page 3131 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 18650 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 18558 Driver or Passenger Seat Back Cushion Finish Panel Replacement Driver or Passenger Seat Back Cushion Finish Panel Replacement Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 7908 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6631 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Locations Hybrid Power Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 10400 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5339 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 12223 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 6335 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 18355 Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Extended Cab) Sunroof Window Height and Opening Fit Adjustment (Extended Cab) 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the adjusting screws on each side of the sunroof window. 4. Adjust the corners of the window panel using the following guidelines: * Adjust the front of the sunroof window flush to 2 mm (0.08 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window flush to 2 mm (0.08 in) above the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Install the sunroof window adjustment screws. Tighten the screws to 5 Nm (44 lb in). Page 6166 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 12816 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 13321 Page 20248 Page 18098 Memory Seat Module (MSM) X5 (AN3) Locations Hybrid Battery Cover: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 8067 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 19866 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 16787 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 14068 Alignment: Testing and Inspection Trim Height Inspection Note Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID) . * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Page 20994 Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13401 Harness Components Page 3076 Fuse Block - Underhood X1 Page 5126 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9573 Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Note Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reference mark the propeller shaft (1), the universal joint strap (2), universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the bolts (3) and the universal straps (2) from the rear axle pinion yoke (5). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the propeller shaft from the rear axle pinion yoke. Page 4791 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 6458 6. Disconnect the EVAP vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 7. Remove the EVAP vent solenoid pipe clip (1) from the frame crossmember. 8. Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1). 9. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle. Page 7997 Actuator: Locations Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle (9.25 inch) Front Drive Axle (9.25 inch) 1 - Front Drive Axle Inner Shaft 2 - Front Drive Axle Inner Shaft Seal 3 - Front Drive Axle Inner Axle Shaft Bearing 4 - Front Drive Axle Inner Shaft Housing 5 - Front Drive Axle Clutch Gear Thrust Washer 6 - Front Drive Axle Clutch Gear 7 - Front Drive Axle Inner Shaft Retaining Ring 8 - Front Drive Axle Clutch Sleeve 9 - Front Drive Axle Clutch Shim 10 - Front Drive Axle Actuator 11 - Front Drive Axle Inner Shaft Housing Bolt 12 - Front Drive Axle Clutch Fork Assembly 13 - Front Drive Axle Clutch Fork Inner Spring 14 - Front Drive Axle Clutch Shaft Bearing 15 - Front Drive Axle Clutch Shaft 16 - Front Differential Carrier Bolt 17 - Front Differential Carrier 18 - Front Differential Carrier Half Location Pin 19 - Front Differential Case Bearing 20 - Front Differential Bearing Adjuster Nut 21 - Front Differential Bearing Adjuster Nut Sleeve 22 - Front Differential Side Bearing Cup 23 - Differential Ring Gear Bolt 24 - Front Differential Side Bearing 25 - Front Differential Pinion Gear Shaft Page 2825 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 9667 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 11033 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Page 12450 Diagrams Security Lamp/Indicator: Diagrams Component Connector End Views Security Indicator Lamp (SPO Alarm) Page 4250 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10942 Correction (See: Brake Rotor Assembled Lateral Runout Correction) . 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools J-45101-100 - Conical Brake Rotor Washers Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J-45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement) . 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer toBrake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) . 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - washers and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Special Tools * J-39544-KIT - Torque-Limiting Socket Set , or equivalent * J-41013 - Rotor Resurfacing Kit * J-42450-A - Wheel Hub Resurfacing Kit * J-45101 - Hub and Wheel Runout Gage * J-45101-100 - Conical Brake Rotor Washers Page 15122 A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 6803 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 18657 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 5321 Spark Plug: Application and ID Ignition System Specifications Page 15272 Control Module HVAC: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 3080 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 1965 1 - Lower Radiator Support 2 - Inflatable Restraint Front End Sensor Front of Vehicle Components (10 Series) Page 742 Page 8881 2-3 Shift Solenoid (SS) Valve (M30) Shift Solenoid (SS) Valve 1 (MW7) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 8606 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 11562 Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) Skid Plate: Service and Repair Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) Oil Pan Skid Plate Replacement (2500/2500 with RPO NZZ) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the mounting bolts for the oil pan skid plate. 3. Remove the oil pan skid plate. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the mounting bolts for the oil pan skid plate. 6. Remove the oil pan skid plate. Installation Procedure Page 5437 5. Install the CMP sensor wire harness (1). 6. Connect the CMP sensor wire harness electrical connector, ensure that the retainer (1) fully engages the CMP sensor. 7. Raise and suitably support the vehicle. Locations Parking Brake Release Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Seals and Gaskets: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 3822 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter (437) if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430). Tighten the drain plug to 25 Nm (18 lb ft). Page 2355 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 11139 8. Lift the master cylinder reservoir (1) straight up and remove the reservoir from the master cylinder. 9. Remove the 3 master cylinder reservoir seals (1). Installation Procedure Page 2642 Page 9463 2. Install the outer bearing into the wheel hub. Note Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 3. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the wheel hub. Note Ensure that the retaining ring is fully and evenly seated in the groove. 4. Install the retaining ring into the groove. Note Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 12661 Page 15079 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. 10. Remove the condenser from the vehicle. Installation Procedure Note If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities (Non-HP2) () for system capacity information. 1. Install the condenser to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the upper insulator retainers and the insulator retainer bolts and tighten to 2.4 Nm (21 lb in) . 3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement) . 4. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft) . 5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to Sealing Washer Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Sealing Washer Replacement) . 6. Install the compressor discharge hose nut to the condenser and tighten to 16 Nm (12 lb ft) . Page 9862 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 2576 Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System Internal Leak Test) andBrake Pedal Travel Measurement and Inspection (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection)Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake Pedal Travel Measurement and Inspection) . 73. If internal leaks are found, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 74. If the brake pedal travel exceeds specification and there is no damage to the pedal system or pushrod, replace the master cylinder. Refer to Master Cylinder Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Overhaul)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) . 75. Turn the ignition switch to ON, without starting the engine. Observe if the brake system warning lamp remains illuminated. 76. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until the brake system is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . 77. Start the engine. 78. Firmly apply the brake pedal several times. Observe the brake pedal feel. 79. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. 80. Drive the vehicle to a speed above 13 km/h (8 mph) to allow ABS initialization to occur. Observe the brake pedal feel. 81. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 18767 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 12314 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 9049 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 7923 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 20365 Page 11864 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 20548 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 5784 * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6558 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) 08-08-49-016C - END OF INFORMATION NEED Fuel Gauge: Technical Service Bulletins 08-08-49-016C - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 08-08-49-016C Date: May 21, 2009 Subject: EI08347 - DTC P0463, Fuel Gauge/Gage Inaccurately Reads Empty, Low Fuel Light On (Diagnose and Repair Using SI) Models: 2008-2009 Buick Lucerne 2008-2009 Chevrolet Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 08-08-49-016B (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. This bulletin is being revised to end the need for dealer feedback. If you encounter a vehicle with this concern, please diagnose and repair using the information found in SI. Disclaimer Page 7934 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 5266 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 1722 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the ECT sensor (1). 3. Remove the ECT sensor. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. Page 18761 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 15695 Air Bag Control Module: Connector Locations Harness Routing Views Body Harness Routing (Crew Cab except HP2) 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 Page 6109 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 10619 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13690 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator Tube Replacement Removal Procedure 1. Remove the oil level indicator (418). 2. Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 3. Remove the oil level indicator tube bolt (419). 4. Remove the oil level indicator tube (420) from the engine block. Note The O-ring seal may be reused if not cut or damaged. 5. Inspect the O-ring seal for cuts or damage. 6. Remove the O-ring seal (421) from the tube, if required. Installation Procedure Page 19353 Component Parts Page 810 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 12708 Page 6016 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 16608 Memory Seat Module (MSM) X3 (AN3) Page 11350 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 10010 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 20251 Page 1401 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 6752 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip to the bracket on the automatic transmission. 13. Install the fuel pipe bracket nut to the bellhousing stud and tighten the nut to 25 Nm (18 lb ft) . 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 15. Lower the vehicle. Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 19396 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3773 Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 5075 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 18808 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 1962 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Passenger Door Components (except AN3/DL3) Page 19541 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 1723 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 15251 A/C Refrigerant Pressure Sensor (HP2) Page 10465 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Selector Switch - O-Ring - Seal 7 - Transfer Case Shift Control Switch Assembly 8 - Transfer Case Front Half 9 - Transfer Case Half Locating Pin 9 - Transfer Case Half Locating Pin 10 - Transfer Case Input Shaft Bearing Assembly 11 - Transfer Case Input Shaft Inner Retaining Ring 12 - Transfer Case High/Low Internal Gear 13 - Transfer Case High/Low Internal Gear Retaining Ring 14 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 15 - Vehicle Speed Sensor Assembly 16 - Vehicle Speed Sensor O-Ring - Seal 17 - Transfer Case Rear Half 18 - Transfer Case Access Hole Plug 19 - Transfer Case - Harness - Bracket 20 - Transfer Case Half Bolt/Screw (Qty: 17) 21 - Transfer Case Rear Output Shaft Bushing 22 - Transfer Case Rear Output Shaft Seal 23 - Transfer Case Oil Fill Plug 24 - Transfer Case Oil Drain Plug 25 - Transfer Case Front Output Shaft Rear Bearing Assembly 26 - Transfer Case Shift Detent Plunger Plug 27 - Transfer Case Shift Detent Plunger Plug O-Ring - Seal 28 - Transfer Case Shift Detent Spring 29 - Transfer Case Shift Detent Plunger 30 Transfer Case Shift Detent Lever Bearing Assembly 31 - Transfer Case Shift Lever Seal 32 Transfer Case Shift Lever 33 - Transfer Case Control Lever Bolt/Screw 34 - Transfer Case Shift Lever - Rubber - Seal Internal Components Page 17495 Page 6939 3. Remove the throttle body nuts (507) and bolts (538). 4. Remove the throttle body (508). 5. Remove and discard the throttle body gasket (509). Installation Procedure 1. Install a NEW throttle body gasket to the intake manifold. Align the tab of the gasket with the notch in the manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the throttle body (508), bolts (538), and nuts (507). Tighten the bolts/nuts to 10 Nm (89 lb in). Page 12988 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 1367 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 7841 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 13644 For vehicles repaired under warranty, use the table. Disclaimer Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 4840 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: Page 10713 Electronic Brake Control Module (EBCM) (JF3/JF7) Page 6937 8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here. Throttle Body Cleaning Throttle Body Cleaning 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Warning Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626, or ACDelco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 5. Perform the throttle learn procedure. Refer to Throttle Learn (See: Throttle Learn) . Page 8626 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 14796 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 5837 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: All Technical Service Bulletins Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 11407 6. Remove all dirt and debris from the electronic brake control module (EBCM) and the brake pressure modulator valve (BPMV). 7. Disconnect the EBCM electrical connector. 8. Loosen, but do not remove, the EBCM bolts (1). Note Do not pry the EBCM from the BPMV. The EBCM must be pulled away from the BPMV evenly. 9. Using the loosened EBCM bolts as a guide, carefully pull the EBCM (1) evenly away from the BPMV to release the electrical connectors. Hybrid Controls Electronic Component Views Control Module: Locations Hybrid Controls Electronic Component Views Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 20132 Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 12814 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6632 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 16307 Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Retractor: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 13640 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 977 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Removal Procedure Note Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Page 6862 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear 09-08-127-001 - END OF INFORMATION NEED Parking Assist Distance Sensor: All Technical Service Bulletins 09-08-127-001 - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-127-001B Date: August 10, 2009 Subject: EI09084 - Rear Parking Assist System Inoperative (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2009 Saturn OUTLOOK All Equipped with Rear Parking Assist (RPO UD7) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-127-001A (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 10348 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 7303 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 17241 Page 5398 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 7300 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17103 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 19938 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 14526 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the lower shock absorber nut and bolt. * Tighten the upper shock absorber bolts to 115 Nm (85 lb ft). * Tighten the lower shock absorber bolts to 115 Nm (85 lb ft). 4. Remove the support from the rear axle. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Page 441 Trailer Brake Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 13013 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 20931 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 2699 Fuse Block - I/P X3 Page 10208 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 12952 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 4423 Drive Motor Generator Battery Control Module X4 (HP2) Page 7099 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 10397 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 14724 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 6652 6. Clear the Min/Max results. 7. Select Normal from the Display Mode. 8. Repeat steps 2 and 4 through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation. Fuel Injector Balance Test with Tech 2 1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure. 6. After the injector stops pulsing, select Min from the Display Mode on theCH-48027 and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 7. Clear the Min/Max results on theCH-48027 . 8. Select Normal from the Display Mode on theCH-48027 . 9. Press Enter on the scan tool to bring you back to the Select Injector screen. 10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation. Pressure Drop Calculation 1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added together. This is the average pressure drop. The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi). ‹› If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector, E-85 only. All other engine, refer toFuel Injector Cleaning (See: Service and Repair/Procedures) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair/Removal and Replacement) Page 20990 Page 17788 Disclaimer Page 4583 Drive Motor Generator Power Inverter Module X6 (Engine Harness) (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Page 20382 Turn Signal Lamp: Diagrams Component Connector End Views Park/Turn Signal Lamp - Lower Left Park/Turn Signal Lamp - Lower Right Page 6274 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 11180 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 6201 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 12201 Fuse Block - Underhood X2 Page 4075 4. Brush or using compressed air, blow away any dirt from around the spark plug. 5. Remove the spark plug. If removing more than one plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Page 14075 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft) . 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 19929 Disclaimer Page 467 Page 4491 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 - Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 - Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Front of Vehicle/Engine Compartment Component Views Page 13722 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.8L and 5.3L) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (6.0L and 6.2L) Page 12381 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7698 7. Remove the range selector lever nut (1). 8. Remove the range selector lever (2). Installation Procedure 1. Install the range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the range selector lever nut (1). Tighten the nut to 25 Nm (18 lb ft). Page 7913 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13134 Fuse Block - Auxiliary X2 (HP2) Page 10473 Transfer Case Actuator: Locations MP 3023/3024-NQH - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 4002 7. Position the CMP sensor wire harness (2) to the front cover. 8. Connect the CMP sensor wire harness to the CMP sensor. 9. Install the CMP sensor wire harness bolts (1). Tighten the bolts to 12 Nm (106 lb in). 10. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.80 in) long to the oil pan to engine block junction. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 15748 Page 11223 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Front Disc Brake Pads Replacement (JD9, JF3, JF7) Brake Pad: Service and Repair Front Disc Brake Pads Replacement (JD9, JF3, JF7) Front Disc Brake Pads Replacement (JD9, JF3, JF7) Page 1518 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 13925 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 10711 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 14939 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 8984 Devices and Sensors Page 4517 Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module 3 Drive Motor Generator Power Inverter Module 4 - Hybrid Powertrain Control Module (HPCM) 5 Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor with Generator Assembly - 1st Position 10 - Drive Motor with Generator Assembly - 2nd Position 11 - Drive Motor Generator Battery 12 - Drive Motor Generator Battery Control Module 13 - Drive Motor Battery Cable Terminal Extension Cover 14 - Transmission Power Inverter Module (3 Phase) Cable Cover 15 - Automatic Transmission Auxiliary Fluid Pump Control Module 16 - Automatic Transmission Auxiliary Fluid Pump Assembly 17 - A/C Compressor Page 4085 Water Pump: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle Components (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 1819 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 13630 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 18417 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Page 8212 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 12590 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 8057 Page 2208 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Page 711 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 6050 Page 19519 Page 12735 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) X300 Chassis Harness to Engine Harness (4.3L) Page 731 Page 4019 6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 7. Remove the EN 46330 . Page 9303 4. Once communication is established and you select the file you want to upload, you will see a screen similar to below. You can email the file directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail" as shown in Figure 11. Figure 12 5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill in the information as requested and then click send. Include the VIN in the subject line. 6. After all the information is entered, hit the send button. After sending the file, you will receive a confirmation box letting you know the e-mail was sent successfully. 7. It is recommended to now save the file to your computer using the same procedure as if you were using TIS 2000 in case your recipient doesn't receive your email with the snapshot data. Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is no way to access your sent mail in TIS2WEB like a regular e-mail program. Sending a Snapshot to GM TAC Page 15553 Inflatable Restraint Sensing and Diagnostic Module (SDM) (MEX) Page 1703 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 20643 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 11550 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions) . 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Page 20434 Page 10977 Brake Shoe: Testing and Inspection Brake Shoe Inspection Inspect the linings every 9 650 km (6,000 mi) and any time the wheels are removed (tire rotation, etc.). Inspect the lining for wear by removing the plug and using the inspection hole. Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Page 12193 Page 586 Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 7420 Page 14344 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 1863 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 7863 Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 13307 Page 19678 Driver/Vehicle Information Display: Diagrams Component Connector End Views Driver Information Center (DIC) Switch (Except MEX/8S8) Page 17917 Disclaimer Page 8906 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Exhaust System - Rattle/Thud Noise On Left Turns/Bumps Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Rattle/Thud Noise On Left Turns/Bumps TECHNICAL Bulletin No.: 09-06-05-004 Date: May 20, 2009 Subject: Rattle or Thud Type Noise During Left Turns or While Driving Over Bumps (Perform Repair as Outlined) Models: 2007-2009 Chevrolet Silverado 1/2 Ton 1500 Series (Including Hybrid) 2007-2009 GMC Sierra 1/2 Ton 1500 Series (Including Hybrid) Condition Some customers may comment on a rattle or thud type noise during left turns or while driving over bumps. Cause This condition may be caused by contact between the front exhaust hanger and the frame hanger. Correction Perform the repair below to eliminate the contact between the front exhaust hanger and the frame hanger. 1. Raise and support the vehicle. 2. Measure the clearance (1) between the front exhaust hanger and the frame hanger. There should be at least 8 mm (0.315 in) clearance. Witness marks may also be visible. - If the clearance is less than specified, proceed to step 3. - If the clearance is within specification, diagnose and repair using the information found in SI. 3. Grind or file the front exhaust hanger head until the remaining material measures 4 mm (0.157 in). 4. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Page 8874 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 19411 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 13590 Page 1176 1 - Horn - Right (7Z1/YE9) 2 - Radiator Core Support 3 - Horn - Left Front of Vehicle Components (10 Series) Page 18452 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 20249 Page 11611 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 12339 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 7847 2-3 Shift Solenoid (SS) Valve (M30) Shift Solenoid (SS) Valve 1 (MW7) Page 11224 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 4748 Drive Motor Generator Battery Control Module X2 (HP2) Page 5588 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (4.3L) Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 1493 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 10878 Brake Pad: Service and Repair Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 8705 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Page 10805 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Page 17939 Page 7332 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 499 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 14472 Page 18614 For vehicles repaired under warranty, use the table above. Disclaimer Page 2981 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 11252 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 12393 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 2850 Page 18336 Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. Remove the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access. 2. It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 20800 For vehicles repaired under warranty, use the table. Disclaimer Page 4120 Page 13335 Fuse Block - Auxiliary, Fuse Holder (Battery Positive Cable) (HP2) Fuse Block - Auxiliary, Fuse Holder (Accessory DC Power Control Module Cable) (HP2) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Page 7395 Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Page 10758 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Front Frame and Underbody Components - 1 of 2 Page 15119 Control Module HVAC: Diagrams HVAC Control Module Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67/C42/MEX) Page 11136 Master Cylinder Replacement (JD9, JF3, JF7) Page 11115 6. If the brake fluid level is at the upper fill level mark, do not add brake fluid to the master cylinder reservoir. 7. Start the engine. 8. As the brake modulator draws brake fluid from the master cylinder reservoir to charge the brake modulator and the HPA, the brake fluid level will decrease. 9. The brake fluid level should be at or above the midway point of the MAX and MIN level marks (2) of the master cylinder reservoir after the brake fluid level stabilizes. 10. If the brake fluid level is at or below the midway point of the MAX and MIN level marks on the master cylinder reservoir after the brake fluid level stabilizes, the brake system should be inspected for wear and possible brake fluid leaks. 11. If the brake fluid level is at or below the midway point of the MAX and MIN level marks on the master cylinder reservoir point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be filled to the MAX level mark. 12. If brake system service was just completed, brake fluid should be added to bring the level in the master cylinder reservoir the MAX level mark. 13. If the brake fluid level is at the MAX level mark, adding brake fluid is not recommended under normal conditions. 14. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Hydraulic Brake System Bleeding (Manual with RPO BRM) Master Cylinder Bench Bleeding (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Master Cylinder Replacement (Vacuum Boost)) . 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Hydraulic Brake System Bleeding (Manual without RPO BRM) Master Cylinder Bench Bleeding (Two-mode Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Page 6824 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3) and tighten to 9 Nm (80 lb in) . 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts and tighten to 2.3 Nm (20 lb in) . 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2) and tighten the screws to 2.3 Nm (20 lb in) . Page 2212 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 7160 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 7235 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 792 Fuse Block - Auxiliary Radiator Cooling Fan Motor Relay: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 11132 4. Connect the brake master cylinder left front brake pipe fitting (1). Tighten the fitting to 30 Nm (22 lb ft). 5. Connect the brake master cylinder right front brake pipe fitting (1). Tighten the fitting to 30 Nm (22 lb ft). Page 10497 Director, Customer and Relationship Services 09241 Page 10715 Electronic Brake Control Module (EBCM) (JH6/JH7) Page 8908 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 3134 Frequently Asked Questions Disclaimer Page 11000 44. If the primary brake pipe port (1) was not fully bled within the 60-second cycle time, press Start to repeat Steps 42-43. 45. Press Enter to continue. 46. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 47. Open the right rear (RR) brake caliper bleeder valve. Ensure the RR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 48. If the RR bleeder valve was not fully bled within the 60 second cycle time, press Start to repeat Step 47 until the brake fluid is clear of any air. 49. Press Enter to continue. 50. Following the instructions on the scan tool, press Start to begin the next bleed sequence. 51. Open the left rear (LR) brake caliper bleeder valve. Ensure the LR bleeder valve is fully bled and securely tightened before the 60-second cycle is completed. Do not leave the bleeder valve open for longer than 60-seconds. 52. If the LR bleeder valve was not fully bled within the 60-second cycle time, press Start to repeat Step 51 until the brake fluid is clear of any air. 53. Press Enter to continue. 54. Secure bleeder hoses to all 4 brake caliper bleeder valves. 55. Bleed each of the 4 brake corners using the J-29532-A orJ 29532 , in the following sequence. Ensure the brake fluid is clear and free of air bubbles at each corner. 1. Left front 2. Right front 3. Left rear 4. Right rear 56. Ensure each of the 4 brake caliper bleeder valves are tightened securely. 57. Press Enter to continue. 58. Remove the J 35589-A and the J-29532-A orJ 29532 from the vehicle. Note The system is active and pressurized, therefore the brake fluid level in the master cylinder reservoir cannot be allowed to be higher than the MAX mark of the operating range. 59. Ensure the master cylinder reservoir is filled no higher than the MAX operating range line. Add or remove brake fluid as necessary. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Replacement (Vacuum Boost)) . 60. Start the engine. 61. Press Start to continue the final sequence. The pump and the HPA circuits are being flushed, and the boost valve is being calibrated and learned by the EBCM through this step. 62. Continue to follow the instructions on the scan tool. 63. Allow the engine to idle for 1 minute to allow the system to recalibrate. 64. Turn the engine OFF, then turn the ignition switch to the ON position without starting the engine. 65. Clear any DTCs from the EBCM. 66. The hybrid brake control modulator is an OBDII compliant module. As such, brake related DTCs may be stored in the powertrain control modules. After addressing any other stored DTCs, clear any brake related DTCs stored in the powertrain control modules. 67. Turn the ignition switch to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 68. Allow the vehicle to remain OFF for at least 1 minute before applying the brake pedal, starting the engine, or performing a test drive. This waiting period is essential to complete the sensor and boost valve calibration and EBCM learn processes, and to allow the HPA to depressurize to allow for a deactivated system pedal feel check. 69. Remove the scan tool from the vehicle. 70. Before starting the engine, firmly apply the brake pedal several times. Observe the brake pedal feel. 71. If the brake pedal feels spongy, perform the following: 1. Repeat the base hydraulic brake system bleeding procedure. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Power Brake Assist/Hydraulic Fluid Accumulator/Service and Repair/Removal and Replacement/Hydraulic Brake Booster Accumulator Replacement) . 2. If the brake pedal feel is now firm, repeat the automated bleeding procedure. 3. If the brake pedal stills feels spongy after repeating the base hydraulic brake system bleeding procedure, inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 72. If the brake pedal stills feels spongy, an if no external brake fluid leaks are found, inspect the brake system for internal leaks and inspect the brake pedal travel. Refer to Brake System Internal Leak Test (Two-mode Hybrid) (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Internal Leak Test)Brake System Internal Leak Test (Non-Hybrid) (See: Testing and Inspection/Component Tests and Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JD9, JF3, JF7) Page 13182 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 2736 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Page 3463 5. Rotate the crankshaft sprocket until the camshaft position (CMP) actuator alignment mark (1) and the crankshaft sprocket alignment mark (2) are aligned. 6. Remove and discard the CMP actuator solenoid valve (234). Component Locations Seat Belt Buckle: Component Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 18831 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 17034 Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Page 9441 * For vehicles equipped the a one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with a two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . Note The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement) . 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) . 16. Remove the support and lower the vehicle. Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Page 3141 7. If all circuits test normal, replace the IPC. Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM replacement, setup, and programming Page 1793 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 17230 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 8319 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 19867 For vehicles repaired under warranty, use the table. Disclaimer Page 15710 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 2632 Page 13400 Module Circuit Function Icons Page 13150 Page 2303 5. Install the spark plug wire to the spark plug. 6. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 7. If a right side spark plug(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 8. If a right side spark plug(s) was replaced, perform the service reconnect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 5155 Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (2). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (1). Page 4158 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 6774 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1) and tighten to 9 Nm (80 lb in) . 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft) . 6. Remove the caps from the fuel and EVAP lines. 7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line. Page 19412 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 12667 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 7038 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 4927 Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas Except LU3/LY6) Page 15984 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 12741 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 9096 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 15120 HVAC Control Module X2 (CJ2) Page 7776 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6282 Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 7. Remove the HO2S (4). Installation Procedure Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 1388 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 12581 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) Left Rear Door Harness Routing (Extended Cab) Page 13661 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 3827 4. Place a suitable drain pan under the oil filter. 5. Remove the oil filter (437). 6. Remove the oil filter adapter (438). Installation Procedure Page 12761 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 9260 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Page 17613 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Diagrams Neutral Safety Switch: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 17543 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Page 3861 Engine Oil Pressure (EOP) Sensor (Gas with 4.3L) Page 6412 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11068 Brake Pipe Replacement (Master Cylinder to ABS Controller) Front Brake Hose Replacement (JD9, JF3, JF7) Page 5254 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 5101 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10385 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 7134 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14871 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 5. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. 7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 9. Support the propeller shaft and move out of the way as necessary. Page 15987 Inflatable Restraint Front End Sensor - Left (10 Series) Page 7133 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8418 Director, Customer and Relationship Services 09241 Page 12208 Fuse Block - Underhood X5 Page 18698 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Note Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Page 14494 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: Page 16712 Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Page 5118 Manifold Absolute Pressure (MAP) Sensor (Gas Except 4.3L) Page 17636 Hood Emblem/Nameplate Replacement (Vortec) Hood Emblem/Nameplate Replacement (Vortec) Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 19421 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 10846 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Page 13233 Junction Block - Left I/P X13 (AN3) Page 18499 Page 319 Memory Seat Module (MSM) X7 (AN3) Page 8836 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 15545 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 - G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Page 7084 5. Install the spark plug wire to the spark plug. 6. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 7. If a right side spark plug(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 8. If a right side spark plug(s) was replaced, perform the service reconnect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 13175 Fuse Block - Auxiliary X1 (HP2) Page 12259 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) Chassis Harness Routing (Except LY6/LMM/HP2) Page 4625 Drive Motor Control Module: Description and Operation Drive Motor Generator Control Module Description and Operation Overview The drive motor generator power inverter module (PIM) assembly converts high voltage direct current (DC) electrical energy to 3 phase alternating current (AC) electrical energy. The accessory DC power control module (APM) converts high voltage DC electric energy into low voltage (14V) and intermediate voltage (42V) in order to charge the vehicles accessory battery and supply electric energy to the 42V power steering system. The APM and PIM are fastened together and are referred to as the drive motor generator control module assembly. The drive motor generator control module assembly is cooled with pre-mixed Dexcool(R) circulating through a cooling system that is separate from the engine cooling system. The hybrid cooling system utilizes a heat exchanger at the front of the vehicle and electric pumps to circulate the coolant. The engine control module (ECM) monitors a temperature sensor in the hybrid cooling system and operates the radiator fan and the hybrid coolant pumps in response to system temperature. High Voltage Circuits Direct Current (DC) The drive motor generator control module assembly is connected to each pole of the high voltage (HV), direct current (DC) drive motor generator battery. Both of the negative and positive HV DC battery poles are isolated from the vehicle chassis by a specific amount of resistance. Each HV DC cable is switched ON or OFF by a high voltage, high current contactor relay contained within the drive motor generator battery assembly. All HV DC negative and positive DC cables are individually shielded and orange in color to alert the technician to the potential presence of high voltage. The electric air conditioning compressor high voltage DC cables are externally connected at the drive motor generator control module assembly. The APM and PIM share an internal connection that supplies the APM with high voltage DC current. Three Phase Alternating Current (AC) Three cables connect each motor generator to the PIM. Each individually shielded cable is orange in color to alert the technician to the potential presence of high voltage. Intermediate and Low Voltage Circuits The APM converts high voltage 300V DC current into both intermediate voltage, 42V, and low voltage, 12V, current. Intermediate Voltage 42V Direct Current Intermediate voltage 42V cables are individually shielded and are blue in color to alert the technician to the potential presence of intermediate voltage. Low Voltage (12V) Direct Current Low voltage (12V) cables on the hybrid-electric vehicle do not require unique coloring or servicing procedures. Drive Motor Generator Power Inverter Module (PIM) Assembly Overview Contained within the PIM assembly are the hybrid powertrain control module (HPCM), and two motor control modules (MCM). Each MCM controls its respective motor generator. All three modules are flash-programmable micro-processors. Hybrid Powertrain Control Module (HPCM) Location The HPCM is a non-serviceable, flash-programmable micro-processor contained within the PIM assembly. Operating Functions The HPCM is the main controller of hybrid operation. The HPCM determines when to perform hybrid operation modes such as engine Auto-stop and regenerative braking. The HPCM also operates in conjunction with the battery energy control module (BECM) to determine when to enable and disable the DC high voltage circuits. Each MCM operates the applicable electric motor generator based upon HPCM commands. Communication and Hosted Diagnostics The HPCM is the host controller for diagnostic trouble code (DTC) information for the following control modules: Page 6990 Ignition Coil 6 (4.8L/5.3L/6.0L/6.2L) Page 19464 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6540 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 17550 1 - X415 2 - J412 3 - J419 4 - Right Hip Lamp Harness 5 - Left Hip Lamp Harness 6 - J418 7 - J413 8 - X416 Page 11840 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17475 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Page 5723 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 18711 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Component Locations Air Bag Control Module: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 15305 Page 10195 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5241 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8220 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Service and Repair Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 5630 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Reg Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Reg Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). Page 8056 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12927 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 7321 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 18827 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12489 Fuse Block - I/P X4 Page 20444 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 11807 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 5068 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 2410 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 4591 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Page 8839 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 2962 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 15323 HVAC Control Module X3 (C67/C42/CJ2/MEX) Page 12468 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 12227 Page 9444 11. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 12. Remove the inner hub bearing. 13. Using a brass drift and a hammer, remove the inner hub bearing cup. 14. Remove the retaining ring from the wheel hub. 15. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing Page 6055 Page 1792 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 14194 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 16770 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Mechanical Specifications Drive/Propeller Shaft: Mechanical Specifications Fastener Tightening Specifications Page 12685 Page 6645 Fuel Injector 6 (4.3L) Fuel Injector 6 (4.8L/5.3L/6.0L/6.2L) Page 6256 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 16032 Seat Occupant Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Interior - Lint Accumulation On Ebony Colored Seats Head Rest: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 10422 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 51 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 19613 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 9006 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 20979 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 6807 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 6872 Page 10179 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14184 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. OnStar(R) - Destination Download Incomplete/Intermittent Global Positioning System: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 12325 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 1093 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 9097 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 12345 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13745 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Headliner Harness (UE1/U3U/UVB) Page 6779 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 10778 Page 9161 Transmission Speed Sensor: Service and Repair Output Speed Sensor Replacement Page 3977 3. Rotate the crankshaft sprocket until the camshaft position (CMP) actuator alignment mark (1) and the crankshaft sprocket alignment mark (2) are aligned. 4. Remove and discard the CMP actuator solenoid valve (234). Page 12516 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Locations Fuel Pressure Control Module: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 11131 2. Install the brake master cylinder seal (1) and the master cylinder to the adapter. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install 2 new brake master cylinder nuts (1). Tighten the nuts to 33 Nm (24 lb ft). Page 7958 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 11093 28. Remove the EBCM (1). Installation Procedure 1. Install the EBCM (1) to the BPMV, if removed. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 5649 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15/25 REG/Ext/Crw Cab With 34 gal Tank) Fuel Tank Pressure Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 14881 Air Door Actuator / Motor: Service and Repair HVAC - Manual Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Page 9930 10 - Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4) 11 - Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plate (Qty: 7) 12 - Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plate (Qty: 8) 13 - Transfer Case Four Wheel Drive Clutch Hub 14 Transfer Case Four Wheel Drive Clutch Shim 15 - Transfer Case Two/Four Wheel Drive Clutch Retaining Ring 16 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Front 17 - Transfer Case Four Wheel Drive Clutch Housing Retaining Ring 18 - Transfer Case Four Wheel Drive Clutch Housing Page 9024 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 7031 Page 9257 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Page 10709 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 2845 Junction Block - Left I/P X12 (except MEX) Page 9434 10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 11. Scribe an alignment line between the pinion shaft and the pinion yoke. 12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J 8614-01 . Page 14246 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 7327 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Locations Hybrid Battery Service Switch: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 12346 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 8843 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7316 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 3591 Some minor scratches may be noticed on the cylinder walls during piston and ring replacement. If the scratch cannot be felt when running your finger nail over it, the scratch is considered normal wear and the block or engine should not be replaced. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5515 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 4893 Engine Control Module (ECM) X2 (Diesel) Page 2146 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Service and Repair Differential Mount: Service and Repair Differential Carrier Assembly Bushing Replacement Tools Required * J 33791 Carrier Bushing Remover/Installer * J 36616 Axle Mount Bushing Remover/Installer Removal Procedure 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement)Differential Carrier Assembly Replacement (2500 4WD) () . 2. Remove the upper differential carrier assembly bushing by performing the following steps: 1. Install the J 36616-2 (1), the J 33791-1 (2), the thrust bearing (3), the J 21474-18 (4), and the forcing screw as shown. 2. Remove the upper differential carrier assembly bushing by holding the forcing screw and slowly tightening the J 21474-18. Page 13872 X350 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) Page 15978 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Passenger Door Components (except AN3/DL3) Page 10995 10. Compute the average of the first and second measurements recorded during the brake applies. Specification Maximum brake master cylinder (BMC) primary piston travel, (measured with the ignition ON, engine OFF, brake modulator and HPA depressurized, and the brakes cool), at a brake pedal apply force of 5,000 kPa (725 psi) : 18 mm (0.71 in). Warning It is recommended that you use the J-29532-A pressure bleeder or a diaphragm type (ball bleeder) which is capable of delivering 200 kPa (30 psi) for the bleed procedure. Follow and read all the directions on the Tech 2(R) for completing the Automated Bleed procedure and do every step during the bleed procedure. If you miss a step, you must start over. The EBCM Relearn will occur during the automated brake bleed procedure, so make sure you maintain battery voltage during the entire procedure. Failure to provide a constant 200 kPa (30 psi) may cause air to be trapped in the brake system and may cause brake performance problems or DTCs to occur. Tool J-29532-A has been tested extensively on this application and has proven to provide the necessary pressure and volume of brake fluid. Vacuum bleeding and other brake bleeding tools are NOT acceptable for this procedure. - If the brake pedal travel is greater than 18 mm (0.71 in), perform the following steps: 1. Inspect the brake system for leaks and visual damage. Repair or replace the components as necessary. 2. Perform the automated brake bleed procedure. Refer to Antilock Brake System Automated Bleed Procedure-Hybrid (HP2) in SI. - If the brake pedal feels spongy and/or the brake pedal travel is still excessive after performing the automated brake bleed procedure and no external brake fluid leaks or damage were found, inspect the hydraulic brake system for internal leaks, etc. Refer to Hydraulic Brake System Diagnosis (Two-mode Hybrid) in SI. 11. Clear all the codes from the modules. 12. Start the vehicle and allow the brake system to pressurize. 13. Drive the vehicle up to 32 km/h (20 mph) and perform several heavy brake stops. 14. Verify that the condition has been corrected. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Page 13585 Fuse Block - Underhood Bottom View Page 9366 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Page 8038 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 13135 Fuse Block - Auxiliary X3 (HP2) Page 5397 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5119 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (4). 3. Remove the MAP sensor retainer. 4. Remove the MAP sensor. Installation Procedure Important: Lightly coat the MAP sensor seal with clean engine oil before installing the sensor. Page 20263 Page 13212 Center Instrument Panel Fuse Block CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 Page 16707 Speaker - Right Rear (Extended Cab/Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Page 2088 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Note Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair) . Page 8774 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2318 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 1680 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 19985 Clearance Lamp: Service and Repair Rear Fender Clearance Lamp Replacement Page 20633 Drive Motor Generator Control Module Sight Shield Replacement Drive Motor Control Module: Service and Repair Drive Motor Generator Control Module Sight Shield Replacement Drive Motor Generator Control Module Sight Shield Replacement Removal Procedure 1. Remove the fender brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . Note Removing the sight shield disengages the High Voltage Interlock Circuit (HVIC). The sight shield mounting fastener must be installed and properly tightened for the HVIC to be closed. Failure to properly tighten the sight shield mounting fastener may result in an open HVIC condition and DTCs. 2. Loosen the sight shield mounting fastener (1) and lift the sight shield from the ball studs (2). Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 3. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . Installation Procedure Page 15250 A/C Refrigerant Pressure Sensor (Diesel) A/C Refrigerant Pressure Sensor (Gas Except HP2) Page 3447 1. Install the a NEW CMP actuator solenoid valve until snug. With the CMP actuator properly positioned onto the camshaft, the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure. Tighten by hand until snug. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the CMP actuator solenoid valve. 1. Tighten the solenoid valve a first pass to 65 Nm (48 lb ft). 2. Tighten the solenoid valve a final pass and additional 90 degrees using J 45059 . 3. Install the CMP actuator magnet. Refer to Camshaft Position Actuator Magnet Replacement (See: Camshaft Position Actuator Magnet Replacement) . Page 10755 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Page 10140 23 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 24 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 25 - Transfer Case Oil Pump Assembly 26 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 27 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 28 - Transfer Case Rear Output Shaft Rear Bearing Assembly 29 Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 30 - Transfer Case Oil Pump Suction Pipe Seal 31 - Transfer Case Oil Pump Suction Pipe 32 - Transfer Case Front Output Shaft Rear Bearing Assembly 33 - Transfer Case Front Output Shaft Driven Sprocket Spacer 34 Transfer Case Front Output Shaft Driven Sprocket 35 - Transfer Case Front Output Shaft Hole Plug 36 - Transfer Case Front Output Shaft 37 - Transfer Case Front Output Shaft Front Bearing Assembly Clutch Components Page 8461 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 13290 Page 12652 Page 10738 Note Do not pry the EBCM from the BPMV. The EBCM must be pulled back evenly. 26. Using the loosened bolts as a guide, carefully pull the EBCM (1) evenly from the BPMV to release the electrical connectors. 27. Remove the EBCM bolts (1). Drivetrain - Clunk Noise At A Stop Or From Launch Drive/Propeller Shaft: Customer Interest Drivetrain - Clunk Noise At A Stop Or From Launch TECHNICAL Bulletin No.: 09-04-21-003D Date: January 14, 2011 Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) Models: 2007-2009 Chevrolet Silverado 1500 Series 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series 2007-2009 GMC Sierra 1500 Series 2008-2009 GMC Yukon, Yukon XL 1500 Series Equipped with 4WD (RPO NQG, NQH) Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-21-003C (Section 04 - Driveline/Axle). Condition Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum. Correction Note Do not use grease for lubrication of the slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. Grease is not compatible with the automatic transmission fluid (ATF) used in the transfer case and can cause damage if mixed. Note The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Rear PropShaft Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear propshaft slip yoke splines. Note Protect the transfer case rear seal from Brake Clean. 3. Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel. 4. Assure that the splines are free of rust or other foreign material. 5. Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 19264717). 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft. Page 16839 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11910 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14737 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Page 20437 Heated Glass Element: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1559 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12377 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 14170 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. Page 13666 Disclaimer Page 20441 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 19514 Component Parts Page 20813 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 3034 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 4978 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 13548 Junction Block - Left I/P X1 (except MEX) Page 12395 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Page 6613 For vehicles repaired under warranty, use the table above. Disclaimer Page 13333 Fuse Block - Auxiliary X2 (HP2) Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Page 3841 Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. For 1500 series vehicles, remove the oil pan skid plate bolts and skid plate, if equipped. 3. For 2500 series vehicles, loosen the 2 rear oil pan skid plate bolts, remove the 2 front oil pan skid plate bolts and skid plate, if equipped. 4. Remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Front Drive Axle/Differential Carrier Assembly Replacement )Differential Carrier Assembly Replacement (2500 4WD) () . 5. Unbolt the steering rack and hang downward. Page 5510 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Parking Brake Shoe Replacement (JD9) Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JD9) Parking Brake Shoe Replacement (JD9) Page 4877 Page 85 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 11460 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Page 9140 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 11599 Positive: Service and Repair Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Service and Repair) . 2. Reposition the positive battery cable insulating cover (2) from over the positive terminal. 3. Rotate the lever lock (1) counterclockwise in order to disconnect the positive battery cable. 4. Remove the positive battery cable terminal (3) from the battery. 5. Remove the auxiliary bussed electrical center (BEC) cover (1). Page 5461 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 10561 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 4956 Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 3706 Tighten the bolt to 50 Nm (37 lb ft). 3. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair/Drive Belt Replacement) . Page 8629 Director, Customer and Relationship Services 09241 Page 7191 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Diagrams Discharge Air Temperature Sensor / Switch: Diagrams Component Connector End Views Inside Air Temperature Sensor (CJ2) Page 10289 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 8946 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 11843 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Hybrid - Reinstalling Hybrid Transmission Drive Motors Wiring Harness: All Technical Service Bulletins Hybrid - Reinstalling Hybrid Transmission Drive Motors INFORMATION Bulletin No.: 10-06-122-001 Date: November 03, 2010 Subject: Reinstalling Hybrid Transmission Drive Motors On 2-Mode Hybrid Full Size Trucks Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with 2ML70 Hybrid Transmission (RPO M99) All Built Prior to VIN Breakpoint 10020698 During service of a 2-Mode hybrid drive motor, the motor harness can easily be damaged if the appropriate precautions are not used. When reinstalling a drive motor, sharp edges of the transmission case access opening may chafe or cut the harness when the drive motor is fed through the case opening. Recommendation Use the procedure and parts below to protect the drive motor harness PRIOR to reinstallation into the transmission case. 1. Remove the black plastic wiring harness clip (1) from the motor casing and pull the harness out of the clip, exposing the drive motor wires (2). Page 5030 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 17688 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20908 Washer Fluid Heater: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 6629 Fuel Injector: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 18822 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 7803 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 18551 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Page 15931 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 1103 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5610 Page 20120 Page 4501 Drive Motor Generator Battery Control Module X5 (HP2) Page 12487 Fuse Block - I/P X2 (except MEX) Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Page 2066 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 12069 Page 20390 Turn Signal Lamp: Service and Repair Parking and Turn Signal Lamp Bulb Replacement (Chevrolet) Page 8231 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 1837 4. Install the CPA retainer (5). 5. Lower the vehicle. Page 2878 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 1123 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 885 Page 14981 Page 6469 4. Open the fuel tank clips (1, 3, 4, and 5) and remove the EVAP lines from the clips. 5. Disconnect the EVAP line quick connect fittings at the fuel tank module and vent valve. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 6. Remove the EVAP lines from the fuel tank. Installation Procedure 1. Install the EVAP lines to the fuel tank. Page 6927 Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Pressure Sensor (Gas Except 4.3L/LY6) Page 12370 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9964 Disclaimer Page 421 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Page 11814 Page 7322 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 3853 23. For 1500 series vehicles, position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 24. Lower the vehicle. 25. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities . 26. Start the engine and inspect for leaks. Page 4898 Engine Control Module (ECM) X3 (HP2) Page 20066 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Page 12478 Page 764 Page 15085 Control Module HVAC: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 9407 Note If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 12. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level Inspection (9.25 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Front Drive Axle) . 13. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 14. Install the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 15. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 17. Lower the vehicle. Page 7215 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 4633 Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 9. Remove the HV dc electric air conditioning compressor module (ACCM) cable terminal fasteners (1). 10. Remove the HV dc electric ACCM cable mounting fasteners (3). 11. Remove the HV dc electric ACCM cable (4) from the PIM distribution box. 12. Remove the HV dc battery cable terminal fasteners (2). 13. Remove the HV dc battery cable mounting fasteners (5). 14. Remove the HV dc battery cable (6) from the PIM distribution box. 15. Inspect and retain the seals (7). 16. Remove the drive motor generator position sensor shield circuit fastener (2). 17. Remove the shield circuit harness (1). 18. Remove the PIM cooling inlet (4) and outlet (5) hoses. 19. Cap the coolant pipes (3, 6) to prevent coolant spillage when lifting the drive motor generator control module assembly from the vehicle. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 6.0 quarts (5.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 14185 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Page 2891 Harness Components Page 14364 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . Page 6255 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the driver's intent based on input from the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default position is slightly open. Modes Of Operation Normal Mode During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations: * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position value, the throttle blade is moved to the Closed position. * Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Battery saver mode-After a predetermined time without engine RPM, the ECM commands the Battery Saver mode. During the Battery Saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited. * Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited. Page 15125 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 5391 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13527 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 8846 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 12211 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 9712 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 17723 5. Slide the trailer brake control relay (1) toward the center of the vehicle and remove the trailer brake control relay. Installation Procedure 1. If installing a new trailer brake control relay, hand start the 2 trailer brake control relay bolts. 2. Position the trailer brake control relay to the frame bracket. 3. Slide the trailer brake control relay (1) toward the left frame rail. Page 2003 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Passenger Seat Components - 1 of 2 Page 11628 Charging System: Specifications Generator Usage Page 20332 Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Roof Beacon Switch (5X7/5Y0/TRW) Page 8059 Page 4746 Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Page 7298 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 745 Page 5763 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 4594 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Engine Block Valley Cover Replacement Intake Manifold: Service and Repair Engine Block Valley Cover Replacement Engine Block Valley Cover Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: )Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: )Intake Manifold Replacement (LY2 and LY6) (See: ) . 2. Remove the engine valley cover bolts (506). 3. Remove the engine valley cover (555) and gasket (556). 4. Remove the O-ring seals (537) from the cover. 5. Remove the oil pressure sensor (706) and washer (707). Installation Procedure Note All gasket surfaces should be free of oil or other foreign material during assembly. Page 1371 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral and Longitudinal Accelerometer Replacement Page 9526 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Page 5789 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 13424 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 4420 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Page 2116 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 6496 See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 29. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. 30. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 15625 Seat Position Sensor: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 7431 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 4524 Drive Motor Generator Battery Control Module X2 (HP2) Page 7787 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Page 2365 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11551 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in) . Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) A/T - Control Valve/Solenoid Cleaning Information Valve Body: All Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information INFORMATION Bulletin No.: 07-07-30-006B Date: March 02, 2010 Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic Transmissions when MIL/DTCs Set Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC, MYD) Supercede: This bulletin is being updated to add models and model years and to advise technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle). The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined to be ineffective. This procedure will be removed from the scan tool and will be no longer available for use. Reference to this procedure will be removed from SI diagnostics and labor operation K9450 will be removed from the Labor Time Guide. Disclaimer Page 13878 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 13627 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 7881 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2386 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12026 Page 10355 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9276 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Page 3108 Fuse Block: Service and Repair 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Page 3821 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Open the hood. 2. Remove the oil fill cap. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Place a oil drain pan under the oil pan drain plug. 5. Remove the oil pan drain plug (430). 6. Allow the oil to drain completely. 7. Clean and inspect the oil pan drain plug, replace if necessary. 8. Clean and inspect the oil pan sealing surface, replace the oil pan if necessary. 9. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. Page 419 Electronic Brake Control Module (EBCM) (JL4 Except 10 Series) Page 7733 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 10612 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 2518 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Page 9970 Disclaimer Page 782 Page 13449 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 18861 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 8114 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 2995 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 5487 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 8085 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 19912 Note Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair) . Page 5613 Page 7141 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Page 17831 Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Page 12343 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 14051 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 16698 1 - Speaker -Right Front Tweeter (except MEX) 2 - Right A-Pillar Trim 3 - Speaker -Left Front Tweeter Connector (except MEX) Passenger Compartment Components - 1 of 2 (Regular Cab) Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 11470 Braking Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Piston Position Sensor (HP2) Page 5816 ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. Page 10740 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the EBCM bolts (1) and tighten in a cross pattern to 3 Nm (27 lb in) . 3. Install the sleeves and insulators to the BPMV, if removed. 4. Install the BPMV assembly to the bracket (1). Page 6844 Page 2846 Junction Block - Left I/P X13 (AN3) Page 4805 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 13592 Page 7415 10 - Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (Qty: 4) 11 - Transfer Case Four Wheel Drive Clutch Pressure - Steel - Plate (Qty: 7) 12 - Transfer Case Four Wheel Drive Clutch Pressure - Friction - Plate (Qty: 8) 13 - Transfer Case Four Wheel Drive Clutch Hub 14 Transfer Case Four Wheel Drive Clutch Shim 15 - Transfer Case Two/Four Wheel Drive Clutch Retaining Ring 16 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Front 17 - Transfer Case Four Wheel Drive Clutch Housing Retaining Ring 18 - Transfer Case Four Wheel Drive Clutch Housing Page 7255 Switches and Relays Page 15489 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Body - Tailgate Handle/Latch Binds/Hard To Open Tailgate Release Handle: All Technical Service Bulletins Body - Tailgate Handle/Latch Binds/Hard To Open TECHNICAL Bulletin No.: 09-08-66-009A Date: May 25, 2010 Subject: Intermittent Pickup Box Endgate Latch Binding, Hard to Open, Does Not Open (Re-Work Endgate Latch Rods) Models: 2009 Chevrolet Silverado 2009 GMC Sierra Supercede: This bulletin is being revised to remove the endgate latch handle re-work. Please discard Corporate Bulletin Number 09-08-66-009 (Section 08 - Body and Accessories). Condition Some customers may comment that the endgate is binding, is hard to open or does not open at all. Applying excessive upward force to the endgate latch handle may allow the endgate to open as designed. Cause This condition may be caused by a fitment concern with the endgate latch rods in the endgate assembly. Correction Re-work the right endgate right latch rod to increase the handle travel. Follow the re-work procedure below. 1. Remove the endgate latch handle bezel. Refer to Pickup Box Endgate Latch Handle Bezel Replacement in SI. 2. Remove the right endgate latch. Refer to Endgate Latch Replacement in SI. 3. Remove the right endgate latch rod. Refer to Pickup Box Endgate Latch Rod Replacement in SI. 4. Remove the foam (1) from the latch rod. 5. Measure the overall length of the rod. Note the measurement. The following steps will instruct how to reduce the overall length of the rod by 3-4 mm (0.118-0.157 in). Page 10247 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9334 Replace the side bearing adjuster lock ring and refer to SI for adjustment. When replacing the side bearing adjuster lock ring, inspect the old locking ring and make sure there are vertical lines in the outer and inner diameter of the ring (1). Next inspect and make sure there is tension when the locking rings are installed. If the locking ring rotates freely around the adjuster, do not use the locking ring. Replace with a new locking ring and make the same inspection. Oversize Lock Rings-Do Not Use The new lock rings will not have any vertical lines (inner or outer). They are imprinted during install. If vertical lines are shown (1), DO NOT USE. Parts Information Refer to GM Parts Catalog. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6227 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 6160 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10137 Transfer Case Actuator: Locations MP 3023/3024-NQH - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 11239 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 12935 Page 7282 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 11126 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the master cylinder reservoir bolts (1) and tighten to 8 Nm (71 lb in) . 7. Connect the brake fluid level indicator switch electrical connector. 8. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Procedures/Master Cylinder Replacement (Vacuum Boost)) . Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (Two-Mode Hybrid) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Note During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container. 4. Disconnect the brake fluid level sensor electrical connector. Page 20525 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 13143 Page 7962 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 5229 Rear Side Door Window Replacement (Crew Cab) Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Crew Cab) Rear Side Door Window Replacement (Crew Cab) Page 3975 12. Remove the J 42386-A (1) and bolts. 13. Install the starter motor. Refer to Starter Replacement (4.8L, 5.3L, 6.0L, and 6.2L) ()Starter Replacement (4.3L) ()Starter Replacement (6.6L) () . 14. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (LH6, LMG, LY2 and LY5) (See: Engine Lubrication/Oil Pump/Service and Repair)Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (Except LH6, LMG, LY2 and LY5) ( See: Engine Lubrication/Oil Pump/Service and Repair) . Page 9229 Valve Body: Locations Disassembled Views Control Valve Upper Body Assembly 320 - Valve Retaining Clip 321 - Valve Retaining Plug 322 - Auxiliary Line Boost Valve 323 Auxiliary Line Boost Valve Spring 324 - 1-3 Clutch Regulator Valve 325 - 1-3 Clutch Regulator Valve Spring 326 - Hybrid Direct 2-3-4 Clutch Regulator Valve 327 - Hybrid Direct 2-3-4 Clutch Regulator Valve Spring 328 - Shift Solenoid Valve - Mode A 329 - Hybrid A/Trans Shift Solenoid Spring 330 - Control Valve Body Locating Pin 331 - Hybrid A/Trans Shift Solenoid Spring 332 Shift Solenoid Valve - Mode B 333 - Actuator Feed Limit Valve Spring 334 - Actuator Feed Limit Valve 335 - Hybrid Low, 1-2 Clutch Regulator Valve Spring 336 - Hybrid Low, 1-2 Clutch Regulator Valve 337 - Hybrid Low, 1-2 Clutch Boost Valve Assembly 338 - Hybrid Low, 1-2 Clutch Boost Valve Spring 339 - Clutch Piston Exhaust Blowoff Ball Valve 340 - Clutch Piston Exhaust Blowoff Ball Valve Spring 341 - Clutch Piston Exhaust Blowoff Ball Valve Plug 342 - Control Valve Body Locator Pin Page 6069 Page 16582 Page 8111 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6128 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 5683 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 1451 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Brakes - Front Brake Induced Pulsation/Vibration Brake Pad: Customer Interest Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Diagrams Battery Cooling Fan Relay: Diagrams Component Connector End Views Generator Battery Vent Fan (HP2) Generator Battery Vent Fan Relay (HP2) Page 5939 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 8855 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 10622 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Page 11714 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10590 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 15026 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 11121 3. Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting. 4. Install the ABS module splash shield (1). Page 10726 6. Install the ABS module splash shield (1). 7. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . Page 11717 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8163 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 11058 Page 13056 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 18556 Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Page 2153 Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 19610 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 20604 Steering/Suspension - Power Steering Fluid Leaking Power Steering Line/Hose: All Technical Service Bulletins Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Capacity Specifications Fluid - Differential: Capacity Specifications AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Page 4721 Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 12057 Fuse Block - Auxiliary (HP2), Top View Page 1742 Page 5370 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 16256 Vehicle Communication Interface Module (VCIM) X3 (UE1 with U3U/UVB) Page 12942 Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 7855 Module Circuit Function Icons Page 15745 Disclaimer Page 8197 Devices and Sensors Page 12964 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 2238 Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear . Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Page 12640 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 15389 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 18640 Disclaimer Page 3903 Tighten the bolts/nuts to 10 Nm (89 lb in). 8. Install the EVAP tube and purge solenoid. 9. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer. 10. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Lubricate the MAP sensor seal with clean engine oil. 12. Install the MAP sensor with a new seal. 13. Install the MAP sensor retainer. Page 9784 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Spark Plug: Specifications Ignition System Specifications Driver or Passenger Seat Back Cushion Cover and Pad Replacement Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Page 11057 Brake Hose/Line: Service and Repair Brake Pipe Replacement (Master Cylinder to ABS Controller) Front Brake Hose Replacement (JD9, JF3, JF7) Page 1482 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 5698 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 12107 Page 1877 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 13445 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 4. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 5. Connect a test lamp between the control circuit and the ignition circuit. 6. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. Page 8875 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 1075 Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 12934 Harness Components Page 7801 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 3514 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Loosen and separate the CMP actuator and timing chain from the camshaft. Position your fingers behind the actuator sprocket and pull the actuator away from the front of the camshaft. Never pull on the reluctor wheel when attempting to remove the actuator. Page 17637 Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 9082 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 5681 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 2994 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1683 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 445 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 5836 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 2. Working through the wheel well opening, disconnect the engine wiring harness electrical connector (3) from knock sensor. 3. Remove the knock sensor bolt (739) and knock sensor (718). Installation Procedure Page 3570 3. Install the USED crankshaft balancer bolt (139). Tighten the USED bolt to 330 Nm (240 lb ft). 4. Remove the USED crankshaft balancer bolt. Note The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in) into the balancer bore. 5. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimension, install the J 41665 and repeat the installation procedure. Page 8820 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 16417 Page 3008 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 12434 Page 4665 Drive Motor Generator Battery Control Module X3 (HP2) Page 13587 Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Electronic Traction Control Switch Replacement Locations Ignition Switch Lock Cylinder: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 1516 Hybrid Battery Service Switch: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 7840 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 11021 Page 17655 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Locations Steering Wheel Heater Control Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 14754 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 1658 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 4066 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure 1. If replacing the right side spark plug wire(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug wire(s) through the wheel opening. 2. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. 3. Remove the spark plug wire from the ignition coil. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the ignition coil. Installation Procedure Page 2664 Fuse Block - Auxiliary (HP2), Bottom View Page 8687 Disclaimer Page 7174 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 5605 Page 17110 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: Customer Interest OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 857 Inflatable Restraint Sensing and Diagnostic Module (SDM) (MEX) A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 12465 Page 18209 Memory Seat Module (MSM) X4 (AN3) Page 7061 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Page 13772 Page 12075 Fuse Block - Underhood X1 Page 20426 Harness Components Page 3441 1. Compress the timing chain tensioner guide and install the EN 46330 . Note * Properly locate the CMP actuator on the locating pin of the camshaft. * The sprocket teeth and timing chain must mesh. * The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. * DO NOT use the CMP solenoid valve again. Install a NEW valve during assembly. 2. Identify the alignment hole (1) in the rear face of the CMP actuator and the locating pin (2) on the front face of the camshaft. Page 9108 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 12623 X176 Inline Harness Connector End Views Page 11559 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 6677 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Disconnect Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) Note There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. * Bartholomew (1) * Q Release (2) * Squeeze to Release (3) * Sliding Retainer (4) * Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . Warning: Refer to Safety Glasses Warning (See: Service Precautions/Technician Safety Information/Safety Glasses Warning) . Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings) 2. Using compressed air, blow any dirt or debris from around the connection. Page 8953 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 11265 Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling) . 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable clip bolt. Page 20212 Page 16072 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 5804 Powertrain Expansion Bus (HP2) Page 14432 Installation Procedure 1. Install the steering shaft upper bearing to the steering column tilt head assembly. 2. Install the steering column shaft assembly. 3. Maneuver and push the steering column tilt head assembly (1) towards the steering column in order to lock the steering wheel lock shoes in place. 4. Lubricate the pivot pins (1) with GM P/N 12346293 (Canadian P/N 992723). 5. Firmly seat each pivot pin (1) into the steering column tilt head assembly. 6. Stake the steering column in 3 locations around each pivot pin. 7. Install anti-rotation pinJ 42640 . Page 13217 Junction Block - Left I/P, Top View Body - Incorrect Sun Visor Label Sun Visor: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 11229 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12966 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 5944 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 17501 Door Latch - Right Rear (Crew Cab) Page 1568 1 - Electronic Adjustable Pedal (EAP) Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 6182 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9051 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 17181 Disclaimer Page 2362 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 11712 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 19910 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 750 Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 4982 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 12973 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 20897 Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer or record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2006-2007 HUMMER H2 1. Open the hood and disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver's side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Bock in the Owner's Manual for fuse information. 2. Locate the under-hood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer Mega fuse. 4. Remove the two nuts (1) for the Mega fuse (2). Refer to the picture. 5. Remove the 60 amp heated windshield washer Mega fuse. 6. Discard the 60 amp heated windshield washer Mega fuse. 7. Install the two nuts back into the two studs. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. Page 8045 Switch Position Icons Page 18260 Seat Climate Control Module X2 (KB6) Page 18289 Page 13458 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4539 23. Remove the sight shield circuit breaker fasteners (1). 24. Remove the sight shield circuit breaker (2). 25. Remove the APM ground strap fastener (2) and ground strap (1). 26. Remove the drive motor generator control module assembly mounting fasteners (3) and retainers (4). 27. Remove the ball studs (1) from the drive motor generator control module. 28. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 29. Lift the drive motor generator control module assembly from the vehicle. 30. To replace the drive motor generator power inverter module (PIM) assembly, refer to Drive Motor Generator Power Inverter Module Removal and Installation (See: Drive Motor Generator Power Inverter Module Removal and Installation) . To replace the accessory DC power control module, refer to Accessory DC Power Control Module Removal and Installation (See: Accessory DC Power Control Module Removal and Installation) . Installation Procedure Page 4248 For vehicles repaired under warranty, use the table. Disclaimer Page 6559 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 4073 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 17228 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 18402 Service and Repair Upper Side Moulding / Trim: Service and Repair Body Panel Paint Protector Replacement (VGC) 1. The paint protective film and vehicle surface temperature should be 13-32°C (55-90°F) for best results. 2. Automatic car washes should be avoided for at least 24 hours after the paint protective film application. 3. Wipe the vehicle surface with isopropyl alcohol or flash naptha at the application area. 4. Dry the surface with a clean lint-free cloth. 5. Create a mixture of 25 percent isopropyl alcohol and 75 percent water and two drops of baby shampoo per 16 oz of fluid mixture. 6. Remove the backing liner from the protective film patch. 7. Use the solution to liberally spray the adhesive side of the protective patch, the mounting location along with your hands. 8. Position the paint protective film patch to the desired location on the vehicle. 9. Spray the surface of the film with the alcohol, water and soap solution. 10. Using a dampened squeegee, start at the center of the protective patch, working outward in order to remove the air and solution from under the protective patch. 11. Release any air bubbles with a pin. 12. Dry the surface with a clean, lint-free cotton cloth. Page 5862 Manifold Absolute Pressure (MAP) Sensor (Gas Except 4.3L) Page 12038 Fuse Block - Underhood X3 Page 6294 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 7528 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 7344 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 9034 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 14928 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 11845 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5600 Page 5928 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Rear Seat Center Belt Buckle Replacement (Ext Cab w/A68) Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Ext Cab w/A68) Rear Seat Center Belt Buckle Replacement (Ext Cab w/A68) Page 769 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers Page 16073 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Resonator Outlet Duct Replacement Removal Procedure 1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Remove the positive crankcase ventilation (PCV) line (1) from the air cleaner outlet duct. 3. Remove the radiator inlet hose clamp clip (2) from the air cleaner outlet duct (1). Page 8577 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 11786 Disclaimer Page 13697 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) Left Rear Door Harness Routing (Extended Cab) Page 11818 Devices and Sensors Page 18756 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 1496 Drive Motor Generator Battery Control Module X3 (HP2) Page 8075 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 18768 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 13689 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 12094 Fuse Block - I/P X4 Page 3320 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 2892 Page 1971 Inflatable Restraint Front End Sensor - Left (10 Series) Page 2181 Door Lock/Window Switch - Passenger X2 (AN3/DL3) Page 1413 3. Ensure that the oil pan drain plug is tight. Tighten the drain plug to 25 Nm (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities . 6. Start the engine and inspect for leaks. Diagrams Oil Level Sensor: Diagrams Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Page 16579 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 7771 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 8685 Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Page 2998 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 860 Page 11141 3. Install the brake master cylinder reservoir pins (1) and tighten to 8 Nm (71 lb in) . 4. Connect the brake master cylinder reservoir return hose quick connect (1). 5. Connect the brake master cylinder reservoir supply hose quick connect (2). 6. Connect the brake fluid level sensor electrical connector. 7. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Procedures/Master Cylinder Replacement (RHD))Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Procedures/Master Cylinder Replacement (Vacuum Boost)) . Master Cylinder Reservoir Filling Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is used for a variety of engine performance enhancements. These enhancements include lower emission output through exhaust gas recirculation (EGR) control, a wider engine torque range, improved gas mileage, and improved engine idle stability. The CMP actuator system accomplishes this by controlling the amount of intake and exhaust valve overlap. For the 6.0 liter (LFA) engine, the park position for the CMP actuator and camshaft is 14.5 degrees after top dead center (ATDC), or 29 crankshaft degrees ATDC. The engine control module (ECM) can only command the CMP actuator to advance the valve timing from the park position, or retard the valve timing back to the park position. The total range of valve timing authority is 23 degrees camshaft rotation, or 46 degrees of crankshaft rotation. The control range is from the park position of 14.5 degrees camshaft, or 29 degrees crankshaft ATDC, to 8.5 degrees camshaft or 17 degrees crankshaft before top dead center (BTDC). CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the control module. The control module sends a pulse width modulated 12-volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage. There are 2 different passages for oil to flow through, a passage for CAM advance and a passage for CAM retard. The camshaft actuator is attached to the front of the camshaft, and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature, engine oil level, and aftermarket engine oil additives can have an adverse affect on camshaft phaser performance. CMP Actuator Solenoid Circuit Diagnostic The engine control module (ECM) monitors the control circuit of the camshaft position (CMP) actuator solenoid for electrical faults. The control module has the ability to determine if a control circuit is open, shorted high, or shorted low. If the control module detects a fault with the CMP actuator solenoid control, DTC P0010 will set. Page 17076 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 18786 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 2955 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4881 Engine Control Module (ECM) X1 (HP2) Page 14065 Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear . Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Page 7748 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 5018 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 3777 Important: Rotate the DT-47731 to engage the EOC pipe fitting's retainer slots. the DT-47731 should be nearly flush with the fitting. 4. Connect the DT-47731 onto the EOC pipe fitting. 5. Rotate the DT-47731 or use the J 28585 until the retainer clip (1) rises above the fitting retainer seat. 6. Pull back on the EOC pipe to disengage the pipe from the EOC pipe fitting. 7. Remove the DT-47731 or the J 28585 from the EOC pipe. Page 8128 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13359 Junction Block - Right I/P (Wire Entry) Page 20560 Heated Glass Element: Electrical Diagrams Defogger Schematics Page 2192 Page 6912 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 11876 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12287 Page 3112 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 18720 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 13471 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 14817 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 577 Page 2828 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 20799 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 12300 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Specifications Thermostat: Specifications Temperature sticks can be used to determine a thermostat's operating range, by rubbing 87°C (188°F) and 97°C (206°F) sticks on the thermostat housing. Use a tempil stick in order to find the opening and the closing temperatures of the coolant thermostat. * J 24731 -188 tempil stick melts at 87°C (188°F). The thermostat should begin to open. * J 24731 -206 tempil stick melts at 97°C (206°F). The thermostat should be fully open. Page 4724 Drive Motor Generator Battery Control Module X4 (HP2) Page 4153 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 19105 Splash Guard: Service and Repair Engine Splash Shield Replacement - Right Side Engine Splash Shield Replacement - Right Side Page 1144 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Page 9000 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 20855 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Page 12212 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 6809 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew cab w/34 Gal Tank) Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew cab w/34 Gal Tank) Page 13028 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 12181 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 8130 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 5669 Page 16807 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 12356 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 19490 Cruise Control: Testing and Inspection Cruise Control Indicator Malfunction (IPC Indicator Malfunction) Cruise Control Indicator Malfunction (IPC Indicator Malfunction) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The instrument panel cluster (IPC) illuminates the cruise control engaged indicator based on serial data messages received from the engine control module (ECM). The indicator is commanded ON when the cruise control system is controlling vehicle speed, and turned OFF with the system disengaged. Reference Information Schematic Reference * Cruise Control Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Cruise Control Description and Operation (See: Description and Operation) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, with a scan tool perform the Lamp Test for the instrument panel cluster (IPC) and observe the cruise control indicator. If the cruise control indicator illuminates during the test, replace the ECM. If the cruise control indicator does not illuminates during the test or remains illuminated at all times, replace the IPC. Repair Instructions Perform theDiagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM or IPC replacement, setup, and programming Page 4667 Drive Motor Generator Battery Control Module X5 (HP2) Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 14708 For vehicles repaired under warranty, use the table. Disclaimer Page 13432 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13331 Fuse Block - Auxiliary X1 (HP2) Page 4621 Drive Motor Generator Battery Control Module X3 (HP2) Page 20913 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 15701 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab without 10 Series) Page 6997 19. The Melco(R) (1) ignition coil is a square design. 20. The Delphi(R) (2) ignition coil is a round design. 21. The Melco(R) ignition coil bracket (1) is a square design. 22. The Delphi(R) ignition coil bracket (2) is a round design. Installation Procedure 1. Position the ignition coil to the ignition coil bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ignition coil bolts. Tighten the bolts to 10 Nm (89 lb in). 3. Install the spark plug wire to the ignition coil. 4. Inspect the spark plug wire for proper installation: * Push sideways on each boot in order the inspect the seating. * Reinstall any loose boot. Page 8744 Switch Position Icons Page 2660 Duct Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Locations Steering Wheel Heater Control Module: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 9487 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . Camshaft Position Actuator Magnet Replacement Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Magnet Replacement Camshaft Position Actuator Magnet Replacement Removal Procedure 1. Remove the water pump. Refer to Water Pump Replacement. 2. Disconnect the engine harness electrical connector from the camshaft position (CMP) actuator magnet. 3. Remove the CMP actuator magnet bolts (751) and magnet (752). 4. Remove and discard the CMP actuator magnet gasket (753). Installation Procedure Note The gasket surface should be free of oil or other foreign material during assembly. Page 18793 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 1973 Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly Oil Cooler: Customer Interest Engine - Oil Leak At Oil Cooler Hose/Pipe Assembly TECHNICAL Bulletin No.: 08-06-02-003A Date: October 27, 2010 Subject: Engine Oil Leak at Engine Oil Cooler Hose/Pipe Adapter to Engine Connection (Diagnose and Repair as Outlined) Models: 2007-2011 Chevrolet Silverado, Suburban, Tahoe 2008-2011 Chevrolet Express 2007-2011 GMC Sierra, Yukon, Yukon XL 2008-2011 GMC Savana Equipped with 4.8L, 5.3L, 6.0L or 6.2L V8 Engine (VIN Code C, M, L, J, 4, 0, 3, 5, K, Y, 8 or 2 - RPO LY2, LH6, LY5, LMF, LMG, LC9, LFA, LY6, L76, L92 or L9H) and Engine Oil Cooling System RPO KC4 Supercede: This bulletin is being revised to clarify the Subject text, add model years, Cause, Correction, graphics and part number information. Please discard Corporate Bulletin Number 08-06-02-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak. Upon further investigation, the technician may find engine oil leaking from the engine oil cooler hose/pipe adapter at the point where it connects to the engine. Cause This condition may be caused by any of the following: - A damaged engine oil cooler hose/pipe adapter gasket, due to a temporary steel sealing device not being removed when the engine oil cooler hose/pipe adapter was first connected to the engine. - Previous oil leak servicing of the engine oil cooler hose/pipe adapter gasket that involved failing to remove the temporary steel sealing device. - Casting porosity at the engine oil cooler hose/pipe adapter bolt holes of the engine. - The engine oil cooler hose/pipe adapter bolts are not torqued to the proper specification. Correction 1. Perform the oil leak diagnosis procedure. Refer to Oil Leak Diagnosis in SI. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 3. The temporary steel sealing device (1) is shown separately from the adapter gasket (2). The temporary steel sealing device SHOULD NOT be installed on the engine or the engine oil cooler hose/pipe adapter. Note Page 8965 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5317 1. Install the spark plug wire to the ignition coil. 2. Install the spark plug wire to the spark plug. 3. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 4. If the right side spark plug wire(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . Page 16012 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3092 Page 12596 X109 Inline Harness Connector End Views X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (Except NQF/NQH/HP2/Late Production with 4.8L/5.3L/6.0L/6.2L) Page 12179 Page 19079 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Page 6838 Fuel Pump and Sender Assembly - Rear (LY6 without NQZ Except MEX) Page 4230 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 8806 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18403 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 7765 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 9476 Drum/Service and Repair/Removal and Replacement) . 11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 12. Remove the support and lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1907 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 12701 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 9708 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 4634 Note The gray side tabs on the accessory dc power control module (APM) assembly connector (2) must be pressed in before rotating the lever. 20. Disconnect the APM assembly connector (2) using the following procedure: 1. Push the green tab. 2. Squeeze the gray side tabs, then rotate the lever. 21. Disconnect the APM assembly connector (3) using the following procedure: 1. Remove the locking tab. 2. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector. 22. Disconnect the remaining APM assembly connector (1). Page 6646 Fuel Injector 6 (Diesel) Page 10253 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 684 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 10556 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 11726 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Locations Seat Heater Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 13728 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Page 3457 A CMP actuator dynamically changes valve timing events relative to piston timing by controlling camshaft position. This is sometimes referred to as variable valve timing or camshaft phasing. Variable valve timing or camshaft phasing does not change duration or lift. * By advancing camshaft timing, an improvement in low end torque can be achieved. * By retarding camshaft timing slightly, an improvement in high end power can be achieved. * By retarding camshaft timing significantly, an improvement in light load fuel economy can be achieved. There are 5 cavities divided by vanes within the CMP actuator. * When oil is directed to the advance cavities (1), the camshaft timing is advanced. * When oil is directed to the retard cavities (2), the camshaft timing is retarded. * When oil is directed to both cavities, the camshaft is held stationary. The 6.0L LFA CMP actuator has a 46 degree range of authority. With the engine not running and no engine oil pressure to the CMP actuator, the high tension spring positions camshaft timing at the 29 degree retard park position. During normal engine operation, and based on performance requirements, the ECM may adjust camshaft timing, as required, within a range from 29 degrees retard to 17 degrees advanced. CMP System Lubrication Flow and Actuator Operation Page 12161 Fuse Block - Underhood X3 Page 9191 Page 19904 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 1783 Page 15370 Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 15561 Air Bag Deactivation Indicator: Diagrams Component Connector End Views Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 Except MEX) Page 10072 5. Lower the vehicle. Input Shaft Seal Replacement Input Shaft Seal Replacement Tools Required * J 36825 Output Shaft Oil Seal Remover * J 23907 Slide Hammer with Bearing Adapter * J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Assembly Replacement) . Important: It may be necessary to use a sharp punch in order to poke a hole into the seal prior to insertingJ 36825 . 2. Using the J 23907 (1), andJ 36825 (2), remove the input seal. Installation Procedure Page 6358 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 8074 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18719 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 2009 Page 20528 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 5627 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Level Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Page 19533 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 13729 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 3926 45. Connect the engine wiring harness electrical connector (4) to the MAP sensor. 46. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid. 47. Install the engine harness retainer to the stud and locator pin. 48. Install the engine harness retainer nut (1) and tighten to 5 Nm (44 lb in) . 49. Install the generator. Refer to Generator Replacement (4.3L) ()Generator Replacement (6.6L) ()Generator Replacement (4.8L, 5.3L, 6.0L, and 6.2L) () . 50. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 6725 Page 10189 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15838 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Locations Steering Control Module: Locations Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 15996 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 7805 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 12632 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 7372 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 20877 6. Cut the five-wire connector from the windshield washer solvent heater assembly. Vary the length of the five wires on the connector. 7. Discard the windshield washer solvent heater assembly and, if install in recall 08048, the jumper harness with inline fuse. 8. Wrap the large connector with two wires in electrical tape. 9. Wrap the red and green wires on the small connector separately. 10. Wrap the five wires on the small connector with electrical tape. Page 961 Director, Customer and Relationship Services 09241 Page 5999 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 11433 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control module electrical connector. Note It is not necessary to completely remove the bolts. 4. Reach above the trailer brake control module and relay bracket and loosen, but do not remove, the trailer brake control module bolts (1). Page 7784 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Locations Seat Memory Switch: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 4841 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 15215 Tighten the bolts to 4 Nm (35 lb in). 5. Connect the electrical harness and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel. Refer to Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . 8. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 9. Install the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Battery Replacement) . 10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) () . 11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 11440 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 7161 Delphi Connectors (12 Way) Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. Page 2333 6. Slowly rotate the crankshaft pulley (1) in a clockwise direction while using finger pressure to pull the belt (2) forward. Ensure that the ribbed area of the belt remains facing forward and the belt aligns properly to the A/C pulley. 7. Inspect the drive belt (1) for proper installation and alignment. Page 12315 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 10147 Page 6283 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). 3. If equipped with 4WD perform the following steps, if equipped with 2WD proceed to step 6. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Install the CPA retainer (2). 6. Connect the HO2S electrical connector (3) to the engine wiring harness electrical connector (5). 7. Install the CPA retainer (2). 8. Lower the vehicle. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 13278 Page 3517 Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. 3. Install the CMP actuator and timing chain. Align the hole in the rear face of the CMP actuator with the locating pin on the front face of the camshaft. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks. Use care to install the actuator completely onto the front of the camshaft. Position your fingers onto the face of the actuator sprocket and push the actuator onto the front of the camshaft. Never push on the reluctor wheel when attempting to install the actuator. Page 851 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series Except ASF/MEX/Crew Cab) Page 1886 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Powertrain Component Views Left Side of the Engine Components (Diesel) Page 12722 X209 Inline Harness Connector End Views X209 Chassis Harness to Rearview Camera Jumper Harness (SVA) Page 20094 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 10743 9. Connect the right supply brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . 10. Connect the left supply brake pipe fitting (2) and tighten to 18 Nm (13 lb ft) . 11. Connect the primary brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . Page 10438 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Testing and Inspection Idler Arm: Testing and Inspection Idler Arm Inspection Special Tools * J 35999 Spring Scale * J 42640 Steering Column Anti-Rotation Pin * J 45101 Hub and Wheel Runout Gage 1. Raise the vehicle on a hoist and support it with jackstands. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 2. Position the wheels straight-ahead and install anti-rotation pinJ 42640 . 3. Install runout gaugeJ 45101 between the idler arm and the vehicle frame. Ensure the runout gage is at zero before taking the measurement. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9605 7. Position the J-9522-5 - U-Joint Bearing Spacer Remover (1) on the universal joint. Note The following procedure is also used for the breaking of the nylon injected ring for those universal joints that are equipped. 8. Using the J-9522-3 - Separator ,J-9522-5 - Remover and a press, remove the universal bearing from the yoke. 9. Rotate the propeller shaft and repeat steps 1-8 to remove the opposite universal joint. Note If the slip yoke is found to be damaged, replace the slip yoke and use a NEW universal joint. DO NOT re-use the old universal joint. 10. Remove the slip yoke (1) from the propeller shaft (2). Page 5154 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Caution: Refer to Heated Oxygen and Oxygen Sensor Caution (See: Service Precautions/Heated Oxygen and Oxygen Sensor Caution) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector (1). 4. Remove the HO2S clip from the engine wiring harness clip (4). Caution: Refer to Excessive Force and Oxygen Sensor Caution (See: Service Precautions/Excessive Force and Oxygen Sensor Caution) . 5. Remove the HO2S (2). Page 12826 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 7864 Engine - Valve Lifter Tick Noise At Start Up Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 13642 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 7272 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 12509 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 7281 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. Page 13600 Fuse Block - I/P Top View Page 10632 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 7954 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11339 Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (5.3L) Power Vacuum Brake Booster Replacement (Adjustable Pedals) Page 12731 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) (U42) Page 496 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 14059 Page 13269 Page 7946 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1659 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 2196 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Page 11793 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 7156 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 12558 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 5688 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 1134 Parking Assist Distance Sensor: Locations Luggage Compartment/Rear of Vehicle Component Views Rear of the Vehicle Components (X88) Page 14083 Electronic Power Steering Motor Control Module X4 (HP2) Page 12479 Fuse Block - Underhood X5 Page 9400 15. Using an inch-pound torque wrench, measure the rotational torque of the pinion it should be between1.0-2.3 Nm (10-20 lb in) for used bearings, or1.7-3.4 Nm (15-30 lb in) for new bearings. 16. If the rotating torque measurement is below1.0 Nm (10 lb in) for used bearings, or1.7 Nm (15 lb in) for new bearings, use the J 8614-01 remover and continue to tighten the pinion nut in small increments until the rotational torque is between1.0-2.3 Nm (10-20 lb in) for used bearings, or1.7-3.4 Nm (15-30 lb in) for new bearings. 17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 18. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles))Differential Replacement (10.5 Inch, 11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Replacement (10.5 Inch, 11.5 Inch Axle)) . 19. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle))Differential Carrier Bearing Preload Adjustment (10.5/11.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Differential Carrier Bearing Preload Adjustment (10.5/11.5 Inch Axles))Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle) (See: Service and Repair/Removal and Replacement/Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)) . 20. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) (See: Service and Repair/Removal and Replacement/Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles))Pinion Depth Adjustment (10.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (10.5 Inch Axle)) . 21. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Backlash Adjustment (8.6 Inch Axle))Backlash Adjustment (10.5/11.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Backlash Adjustment (10.5/11.5 Inch Axle))Backlash Adjustment (9.5 LD Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Backlash Adjustment (9.5 LD Axle)) . 22. Fill the axle with lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 23. Remove the support and lower the vehicle. Body - Door Module/Switch Programming Information Door Module: All Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 4088 Generator Control Module Coolant Pump - Left (HP2) Page 13410 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17718 Trailer Brake Control Module (JL1 with 31 Series) Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Page 15368 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 5039 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14902 Air Door Actuator / Motor: Service and Repair Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Page 3978 Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves. 5. Remove the CMP actuator (235) and timing chain (208). Page 7568 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 20438 Page 12495 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 10319 Page 19252 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Page 7204 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 5659 Harness Components Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 9797 Disclaimer Page 7348 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 20818 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Page 12689 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L Except NQF/NQH/HP2) Page 11245 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 4087 Generator Battery Vent Fan (HP2) Generator Battery Vent Fan Relay (HP2) Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: Page 1755 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 18924 Page 5592 Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 11615 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (With V8 Engine) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Battery Cable/Negative/Service and Repair) . Page 6111 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 13604 Fuse Block - I/P X3 Page 9106 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 18668 Front Seat Cushion Outer Trim Panel Replacement (Manual) Front Seat Cushion Outer Trim Panel Replacement (Manual) Page 12304 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 7270 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4160 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) . Page 19551 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 18044 Page 2953 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 16746 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 9070 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5988 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 3440 4. Remove the CMP actuator (235) and timing chain (208). 5. Insert and secure a tie strap (1) through the center of the actuator and over the reluctor wheel. Installation Procedure Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 12196 Page 6780 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 Nm (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the bolt to 20 Nm (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . Page 2557 10. Position the drain pan under the oil filter. 11. Remove the oil filter. 12. Ensure that the oil filter gasket is still on the old filter (437) if not, remove the oil filter gasket from the oil pan. Installation Procedure 1. Apply clean engine oil to the NEW oil filter seal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). 3. Tighten the oil pan drain plug (430). Tighten the drain plug to 25 Nm (18 lb ft). Page 8798 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 9523 2. Install the outer bearing into the wheel hub. Note Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 3. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the wheel hub. Note Ensure that the retaining ring is fully and evenly seated in the groove. 4. Install the retaining ring into the groove. Note Page 1489 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 736 Page 1152 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in) . 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 4199 Page 7932 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 12503 Page 7732 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 11602 1. Install the positive battery cable assembly (1) to the vehicle. 2. Install the positive battery cable leads to the mega fuse and auxiliary BEC studs. 3. Connect the positive battery cable connector (2) to the underhood BEC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the positive battery cable nut (3) to the auxiliary BEC stud and tighten to 9 Nm (80 lb in) . 5. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in) . Page 17222 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 523 Page 18712 For vehicles repaired under warranty, use the table. Disclaimer Page 6914 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (HP2) Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Page 13716 Page 12981 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 18781 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 6029 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 16631 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 9927 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case High/Low Shift Fork Pad 11 - Transfer Case High/Low Shift Fork 12 - Transfer Case High/Low Shift Fork Spring Assembly 13 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 14 - Transfer Case Two/Four Wheel Drive Actuator Cam Spacer 15 - Transfer Case Two/Four Wheel Drive Actuator Cam 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case High/Low Shift Fork Pin 18 - Transfer Case Actuator Shaft Gear 19 - Transfer Case Rear Output Shaft Assembly 20 - Transfer Case Front Output Shaft Drive Chain Assembly 21 - Transfer Case Front Output Shaft Drive Sprocket 22 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly Page 12296 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 10180 Rear Bumper Impact Bar Replacement Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Rear Bumper Impact Bar Replacement Page 563 Page 6083 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 11127 5. Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside. 6. Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside. 7. Disconnect the brake master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. Page 12051 Fuse Block - I/P X2 (except MEX) Page 45 Disclaimer Page 19819 Fuel Gauge Sender: Locations Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 20969 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 8009 23 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Inner 24 - Transfer Case Front Output Shaft Drive Chain Assembly 25 - Transfer Case Front Output Shaft Drive Sprocket 26 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 27 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 28 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 29 - Transfer Case Oil Pump Assembly 30 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 31 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 32 Transfer Case Rear Output Shaft Rear Bearing Assembly 33 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 34 - Transfer Case Oil Pump Suction Pipe 35 - Transfer Case Oil Pump Suction Pipe Seal 36 - Transfer Case Front Output Shaft Driven Sprocket Spacer Spring 37 Transfer Case Front Output Shaft Driven Sprocket Spacer 38 - Transfer Case Front Output Shaft Driven Sprocket 39 - Transfer Case Front Output Shaft Hole Plug 40 - Transfer Case Front Output Shaft 41 - Transfer Case Front Output Shaft Front Bearing Assembly Page 2032 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (With LU3) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With V8 Engine) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (With LMM) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair) . 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 850 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series with Crew Cab Except ASF) Page 6268 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.3L) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (4.8L/5.3L/6.0L/6.2L) Page 2656 Page 6680 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. Page 13845 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (4.3L) Page 7469 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 11423 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Component Locations Seat Position Sensor: Component Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 16354 Disclaimer Page 20413 For vehicles repaired under warranty, use the table. Disclaimer Page 2214 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Page 8681 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. Restraints - Air Bag Readiness Light On. Parking Brake Cable: Customer Interest Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 4873 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 13781 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Page 13351 Junction Block - Left I/P X8 (except MEX) Page 16930 Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Page 14499 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 7262 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9877 Input Speed Sensor (ISS) (M30) Page 3669 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 2821 Fuse Block - Auxiliary X1 (HP2) Page 1644 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 4474 Page 8214 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 16810 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 20609 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 17720 Trailer Brake Control Relay (JL1) Trailer Brake Control Switch (JL1) Page 13403 Page 12420 Fuse Block - Auxiliary (HP2), Bottom View Page 1753 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (15/25 Reg/Ext/Crw Cab With 34 gal Tank) Fuel Level Sensor Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Page 20388 Tail/Stop and Turn Signal Lamp - Upper Right Page 8495 Disclaimer Page 6187 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Page 4528 Page 16209 Disclaimer Page 11032 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Page 8586 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 11978 Disclaimer Page 11927 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 19623 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7410 Transfer Case Actuator: Locations MP 3023/3024-NQH - Transfer Case Transfer Case Disassembled View Case Half Components Case Half Components 1 - Transfer Case Front Output Shaft Seal Page 10789 36. Press Start to begin the next bleed sequence. The brake modulator to master cylinder, or intermediate, brake circuits are being port bled during this sequence. Ensure each of the 2 intermediate brake pipe ports (1) is fully bled and securely tightened before the 60-second cycle is completed. 37. Loosen, but do not disconnect, one of the 2 intermediate brake pipe fittings (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 38. Tighten the first brake pipe fitting, then loosen, but do not disconnect, the second intermediate brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 39. Tighten the second intermediate brake pipe fitting. 40. If both of the intermediate brake pipe ports (1) were not fully bled within the 60-second cycle time, press Start to repeat Steps 37-39. 41. Press Enter to continue. The brake master cylinder to brake modulator, or primary, brake circuit is being port bled during this sequence. Ensure the primary brake pipe port (1) is fully bled and securely tightened before the 60-second cycle is completed. 42. Loosen, but do not disconnect, the primary brake pipe fitting (1). Keep the connection open just long enough to expel the air trapped in this circuit; about 15-20 seconds. 43. Tighten the primary brake pipe fitting (1). Page 12723 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (HP2/Late Production except Y91/MEX/8S8) Page 7781 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 14927 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 534 Page 1293 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair) . 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair) . Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 12880 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 12079 Page 6662 19. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 20. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 21. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 22. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail. 23. Remove the EVAP tube and purge solenoid. Page 3116 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Page 7874 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 2243 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 3913 25. Remove the positive crankcase ventilation (PCV) hose from the intake manifold fitting. 26. Position the hose out of the way. 27. Loosen the intake manifold bolts (512). Note The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness. 28. Remove the intake manifold (500). 29. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages. Page 11654 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 8115 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 20503 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Diagrams Power Distribution Module: Diagrams Component Connector End Views Accessory DC Power Control Module X1 (HP2) Accessory DC Power Control Module X2 (HP2) Page 4030 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 1795 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (4.3L) Manifold Absolute Pressure (MAP) Sensor (Diesel) Page 12788 Page 8753 Page 8417 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 17937 Page 19198 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Page 20524 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1899 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: Customer Interest Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 18806 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. Drivetrain - Front Axle Vent Hose Routing Differential Case: Technical Service Bulletins Drivetrain - Front Axle Vent Hose Routing INFORMATION Bulletin No.: 08-04-19-004A Date: January 06, 2010 Subject: Correct Front Axle Vent Hose Routing Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL with Four Wheel Drive or All Wheel Drive Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 08-04-19-004 (Section 04 - Driveline/Axle). The front axle vent hose is mounted in the left side of the engine compartment, and may not be correctly routed. The vent hose can get misrouted and placed in a position that is lower than the front axle harness/engine harness in-line connector. In this position, the vent tube may ingest water. The front axle vent hose may be routed to the wheel side of the wheel well. It may be hanging through the opening of the wheel well in a vertical position, with the vent cap hanging down. If you encounter a vehicle with the front axle vent hose misrouted, reroute the hose to the correct location. The hose should be mounted inside the engine compartment, in an upward position to prevent the possibility of water being drawn into the hose and axle assembly during cool-down. Tape the vent hose to the nearby wiring harness as shown. Technicians should also change the front axle fluid. Parts Information Warranty Information Page 8177 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 20330 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Page 9490 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Page 2911 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 13743 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 20915 Page 7696 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Page 14899 Page 20905 Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the GM Customer Assistance Center. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10153 Division Owner Letter Division Owner Letter Page 2198 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 19543 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 18809 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 19398 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 1611 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Diagrams Television / Monitor: Diagrams Component Connector End Views Video Display (U42) Page 8255 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19030 Power Seat Switch: Connector Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 8867 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 13583 Page 18742 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 20507 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 20645 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3/DL3) Door Lock Switch - Passenger (AU3 without AN3/DL3) Page 13867 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (D07 with UQ3 or AZ3/HP2) Page 8194 Component Parts Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 18961 Door Lock/Window Switch - Driver X1 (AN3/DL3) Door Lock/Window Switch - Driver X2 (AN3/DL3) Page 17105 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 6093 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 5433 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Page 19367 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Drive Motor Battery Components Drive Motor Control Module: Locations Drive Motor Battery Components Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label Page 9512 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Page 16285 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11821 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 8991 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 2633 Page 8985 Page 4940 Fuel Pump Relay: Locations Wheels/Vehicle Underbody Component Views Wheels/Vehicle Underbody Component Views Left Side Frame and Underbody Components (Gas with LY6) 1 - Fuel Pump and Sender Assembly -Rear 2 - Fuel Pump and Sender Assembly -Front 3 - Fuel Pump Relay -Secondary Left Side Frame and Underbody Components (Except HP2) Page 8272 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2533 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 18514 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 741 Engine Control Module (ECM) X2 (4.8L/LY6 or 6.2L with Y91) Page 10919 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Locations Battery Current Sensor: Locations Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label 10 - Drive Motor Battery Cable Assembly Nut 11 - Drive Motor Battery Positive Relay Cable Assembly Page 13300 Page 12062 Fuse Block - Auxiliary X3 (HP2) Page 13576 Junction Block - Rear Lamps X4 Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: Customer Interest Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 3038 Junction Block - Left I/P X1 (except MEX) A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 10437 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7203 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5304 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 17815 Carpet: Service and Repair Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 9450 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft) . 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle) . 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with the two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (10.5 Inch Axle))Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (11.5 Inch Axle))Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (8.6 Inch Axle))Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Oil Replacement (9.5LD Inch Axle)) . 9. Remove the support and lower the vehicle. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Fluid Pump: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 2510 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear drive axle. * Use the proper fluid, refer toApproximate Fluid Capacities . * For the proper capacity, refer toFluid and Lubricant Recommendations . 3. Install the fill plug and tighten to 33 Nm (24 lb ft) . 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure Page 11443 Page 10218 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3642 5. Install the valve rocker arm cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Tighten the rocker arm cover bolts. Tighten the bolts to 12 Nm (106 lb in). 7. Install the PCV tube (1) to the valve rocker cover (2). Page 9926 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor O-Ring - Seal 15 - Transfer Case Rear Half 16 - Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Actuator Shaft Position Sensor Bolt/Screw 22 - Transfer Case Actuator Shaft Position Sensor Assembly 23 - Transfer Case Actuator Shaft Position Sensor - O-Ring - Seal 24 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 25 - Transfer Case Two/Four Wheel Drive Actuator Assembly 26 - Transfer Case Two/Four Wheel Drive Actuator Seal 27 - Transfer Case Oil Drain Plug 28 - Transfer Case Oil Fill Plug 29 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 30 Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Internal Components Page 7485 Director, Customer and Relationship Services 09241 Page 7190 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 18339 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . Page 17833 Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Page 2706 The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Fuse 11 ................................................................................................................. ...................................................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 1702 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 11149 6. Install the brake pushrod retainer bolt (1), if equipped and tighten to 10 Nm (89 lb in) . 7. Connect the BMC primary piston position sensor electrical connector. 8. Install the master cylinder seal (1), if removed. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing. Page 471 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 15959 29. Connect the deployment harness to the seat belt pretensioner connector. 30. Route the deployment harness out of the passenger's side of the vehicle. 31. Completely cover the windshield and the front door openings with a drop cloth. 32. Deploy each deployment loop one at a time. 33. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length. 34. Place a power source, 12 volt minimum/2 amp minimum, such as a vehicle battery, near the shorted end of the harnesses. 35. Separate one set of wires and touch the wire ends to the power source in order to deploy the seat belt pretensioners. 36. Disconnect the deployment harness from the power source and twist the wire ends together. 37. Continue the same process with the remaining deployment harnesses that are available. 38. Remove the drop cloth from the vehicle. 39. Disconnect all harnesses from the vehicle. 40. Discard the harnesses. 41. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 42. If one or more of the seat belt pretensioners did not deploy, perform the following steps to remove the undeployed seat belt pretensioner from the vehicle, refer toSeat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)) . 43. Call the Technical Assistance Group for further assistance. Page 16737 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 18322 Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . Tighten the screws to 4 Nm (35 lb in). 2. Install the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)) . Tighten the motor attachment screws to 3.5 Nm (31 lb in). 3. Connect the electrical connector to the motor/actuator. 4. Remove the pin (1) from the holes that held the position while installing the drive motor. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair )Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair)Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair) . 6. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Programming and Relearning)Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Programming and Relearning) . 7. Verify the operation of the sunroof. Page 5951 Body Control Module (BCM) X3 Page 2636 Page 543 Specifications Spark Plug: Specifications Ignition System Specifications Page 8426 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 13117 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 6244 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10130 Internal Components 1 - Transfer Case High/Low Planetary Carrier Retaining Ring 2 - Transfer Case High/Low Locking Plate 3 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 4 - Transfer Case Input Shaft 5 - Transfer Case Input Shaft Pilot Bearing Assembly 6 - Transfer Case Input Shaft Pilot Bearing Retaining Ring - HD and SHD Only 7 - Transfer Case Planetary Carrier Sun Gear Thrust Washer 8 - Transfer Case High/Low Planetary Carrier Assembly 9 - Transfer Case High/Low Clutch 10 Transfer Case Two/Four Wheel Drive Synchronizer Sleeve 11 - Transfer Case Two/Four Wheel Drive Shift Fork Inserts 12 - Transfer Case Shift Fork Spring 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case High/Low Shift Fork 15 - Transfer Case High/Low Shift Fork Inserts 16 - Transfer Case Control Actuator Shaft 17 - Transfer Case Shift Detent Lever Assembly 18 - Transfer Case Rear Output Shaft 19 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 20 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 21 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 22 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking Ring - Outer Page 11471 Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Page 706 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 9038 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20902 11. Connect the large two-wire connector (1) to the body harness (2). 12. Connect the small five-wire connector (1) to the body harness (2). 13. Secure the large two-wire connector and small five-wire connector to the windshield washer solvent heater assembly bracket. 14. Connect the two windshield wiper solvent inlet and outlet hoses together. Use a portion of the rubber wiper solvent hose removed in Step 1 if needed to join the two plastic wiper solvent hoses together. Discard the remaining portions of the rubber windshield wiper solvent hoses. 15. Route and secure windshield wiper solvent hose along passenger side front fender. Page 8137 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 12225 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Page 5902 Note A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the HO2S (3). Tighten the sensor to 42 Nm (31 lb ft). 3. Connect the HO2S electrical connector (7) to the engine wiring harness electrical connector (6). Page 13877 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9/HP2 without AN3/DL3) Page 11545 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 8365 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Fluid Pump: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 8834 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 5614 Page 1268 Seat Adjuster Switch - Passenger (AN3) Page 2975 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2160 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 19 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 8607 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10318 Switches and Relays Page 12627 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 8302 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 10292 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 20982 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 3829 4. For 2500 series vehicles, position the oil pan skid plate and tighten until snug the 2 rear oil pan skid plate bolts, install the 2 front oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 5. For 1500 series vehicles, position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 6. Lower the vehicle. 7. Refill the engine oil. Refer to Approximate Fluid Capacities and/or Fluid and Lubricant Recommendations . 8. Start the engine and inspect for leaks. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 3490 Lifter / Lash Adjuster: Service and Repair Valve Lifter Oil Manifold Replacement Valve Lifter Oil Manifold Replacement Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (See: Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. DO NOT lift the valve lifter oil manifold by the electrical lead frame. Page 12367 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11064 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Page 1807 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools J 41712 Oil Pressure Switch Socket Removal Procedure 1. Remove the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . 2. Disconnect the engine harness electrical connector (1) from the oil pressure sensor. 3. Using the J 41712 or equivalent, remove the oil pressure sensor (706) and washer (707). Installation Procedure Page 15165 7. Remove the evaporator core (1) from the upper HVAC module assembly (2). Installation Procedure Note If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities (Non-HP2) () . 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1) 3. Install the evaporator cowl gasket to the evaporator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the screws to the HVAC module assembly. Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (See: Housing Assembly HVAC/Service and Repair) . Page 8477 Page 10431 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 5757 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13546 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Page 9853 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 12165 Fuse Block - Underhood X5 Page 5729 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 6858 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 6517 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis (W/O FPCM) Fuel System Diagnosis (w/o FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Fuel Pressure Gage * J 37287 Fuel Line Shut-Off Adapters Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer toFuel System Diagnosis (w/o FPCM) Fuel System Diagnosis (w/FPCM) (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 2. Ignition OFF, all accessories OFF, install theCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 3. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: Page 9483 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Page 14518 3. Using theCH-48845 (1), compress the front spring (2). 4. Using the appropriate size wrench, hold the shock absorber shaft. Note Page 14074 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications) . When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Page 16435 Other USB Device Supported Requirements (X = Supported; - = Not Supported) Disclaimer Page 2759 Page 13803 Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Page 6664 26. Remove the fuel injector retainers (1). 27. Remove the fuel injectors (3) from the fuel rail. 28. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4). Installation Procedure 1. Lubricate the NEW fuel injector O-ring seals with clean engine oil. 2. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors. 3. Install the fuel injectors (3) into the fuel rails. 4. Install the fuel injector retainers (1). Page 89 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 7939 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 20497 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Left Rear Frame and Underbody Components - 1 of 2 1 - Trailer Connector (UY7) 2 - Chassis Harness 3 - Camper/Trailer Harness 4 - Camper Trailer Blunt Cuts (UY2) Left Rear Frame and Underbody Components - 2 of 2 Page 9231 Valve Body: Service and Repair Control Valve Upper Body Replacement Removal Procedure 1. Remove the control solenoid valve and transmission control module assembly. Refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement (See: Extension Housing/Service and Repair/Control Solenoid Valve and Transmission Control Module Assembly Replacement) . 2. Remove the manual shift detent spring bolt (4). 3. Remove the manual shift detent spring (5). 4. Remove the control valve upper body bolts (3). 5. Remove the control valve upper body (2). 6. Remove and discard the control valve upper body seal assembly (1). 7. Remove and discard the fluid pump seals (6). Page 20938 Page 1823 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 18222 Page 17841 Page 17107 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 2011 Page 6760 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the fuel/EVAP line bracket bolt (1) and tighten to 9 Nm (80 lb in) . 5. Install the fuel/EVAP line clip nut (2) and tighten to 20 Nm (15 lb ft) . 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. Page 13246 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Page 11262 6. Lower the vehicle. 7. Apply and release the park brake pedal 3 times. Page 2145 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 334 Page 3999 6. Remove the front cover bolts (501). 7. Remove the front cover (502) and gasket (503). 8. Discard the front cover gasket. 9. Remove the crankshaft front oil seal. 10. If replacing the engine front cover perform the following steps, otherwise proceed to step 10 of the installation procedure. 11. Remove the CMP sensor wire harness bolts (1). 12. Disconnect the CMP sensor wire harness from the CMP sensor. 13. Remove the CMP sensor wire harness (2). Page 2007 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 1620 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Page 5323 * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3). Refer to Ignition System Specifications (See: Ignition System/Specifications) . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition System/Specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak ignition coils * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark plug intensity. Most powdery deposits will not affect spark plug intensity unless they form into a glazing over the electrode. Page 13824 Page 14067 If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 7723 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14448 Note Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock and 9 o'clock positions, gently push in on one side of the tire to remove any lash. 7. Zero the dial indicator. 8. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 9. Record the measurement seen on the dial indicator. 10. If the measured value exceeds 0.5 mm (0.02 in) then replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (Two Mode Hybrid) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement)Steering Linkage Inner Tie Rod Replacement (Hydraulic power Steering) () . 11. Repeat the procedure for the other side. Page 9005 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16690 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 8594 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Page 19605 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 6989 Ignition Coil 5 (4.8L/5.3L/6.0L/6.2L) Page 15354 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Page 10871 Page 5750 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 18867 Page 10440 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 4447 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 8788 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 4540 1. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 2. Lift the drive motor generator control module assembly into the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Remove the lifting device and install the ball studs (1). Tighten the ball studs to 10 Nm (89 lb in) . 4. Install the drive motor generator control module assembly retainers (4) and mounting nuts (3). Tighten the mounting nuts to 9 Nm (80 lb in) . 5. Install the APM ground strap (1) and APM ground strap nut (2). Tighten the nut to 9 Nm (80 lb in) . Page 8794 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 18845 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14891 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Page 13761 X278 Inline Harness Connector End Views X278 Instrument Panel harness to Body harness (MEX/A52) Page 11078 Page 4742 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 3607 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 6047 Page 1398 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 4710 Drive Motor Generator Power Inverter Module X6 (Engine Harness) (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Page 8613 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Page 6144 7. Lower the vehicle. 8. Using a small flat bladed tool, disengage the CMP sensor wire harness electrical connector retainer (1) from the CMP sensor. 9. Remove the CMP sensor wire harness (1). Page 13882 X700 Body Harness to Left Rear Door Harness (Crew Cab) Page 16103 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 787 Page 12040 Fuse Block - Underhood X4 Tire Monitor System - Tire Pressure Light Stays ON Door Module: Customer Interest Tire Monitor System - Tire Pressure Light Stays ON TECHNICAL Bulletin No.: 08-03-16-004A Date: January 29, 2009 Subject: Tire Pressure Light Stays On (Reprogram RCDLR) Models: 2008-2009 Buick Lucerne 2008-2009 Cadillac CTS, DTS, Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2009 Saturn VUE with Vehicle Build Dates Between January 1, 2008 and August 15, 2008 Supercede: This bulletin is being revised to add the Avalanche and 2009 Saturn VUE to the models. Please discard Corporate Bulletin Number 08-03-16-004 (Section 03 - Suspension). Condition Some customers may comment that the tire pressure light stays on even though tire pressure values are correct. It should also be noted that no DIC messages have been displayed and a scan tool will reveal no DTCs within the RCDLR. Correction Important: From the controller list, select RCDLR Remote Control Door Lock Receiver (Pass-Thru Only). If all the above conditions have been met, then reprogram the RCDLR. A revised service calibration has been released to address this issue. Reprogram the RCDLR using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Important: The Copy and Paste TPM Information function in Tech 2(R) must be used when reprogramming the RCDLR. This function can be used to copy all the information that is related to the tire pressure monitoring system (including tire sensor ID's) and paste the information into a freshly SPS reprogrammed RCDLR. Refer to Remote Control Door Lock Receiver Programming and Setup in SI for additional information. Warranty Information Disclaimer Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Symbols Voltage Indicators General Icons Page 13510 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 8816 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 1841 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Page 2148 Page 15703 Page 9138 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Diagrams Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Page 13760 X215 Inline Harness Connector End Views X215 Body Harness to I/P Harness (HP2) Page 16862 Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter shown in this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2009. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Page 6131 10. Connect the CMP sensor wire harness electrical connector (1) to the CMP actuator magnet. 11. Connect the engine wiring harness electrical connector (3) to the CMP sensor wire harness. 12. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Page 5280 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 7975 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 5199 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 2786 Page 16718 Radio Rear Side Door Speaker Replacement (Crew Cab) Radio Rear Side Door Speaker Replacement (Crew Cab) Page 2708 Junction Block - Left I/P, Bottom View Page 19902 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 9380 2. Move the shaft back and forth and read the end play. The correct end play is 0.03-0.51 mm (0.001-0.020 in). 3. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range. Page 9137 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 4541 6. Install the sight shield circuit breaker (2) and secure with bolts (1). Tighten the bolts to 5 Nm (44 lb in) . 7. Connect the APM assembly connectors (1 and 3) and install any removed locking tabs. 8. Connect the APM assembly connector (2) using the following procedure: 1. Push the lever up. Note Install the connector (2) without disturbing the position of the lever. DO NOT use the lever to install the connector in place. 2. Install the connector (2) onto the terminals by pushing on the connector only. 3. Rotate the lever after the terminals are engaged. 4. Push the green tab to lock the lever. Page 7865 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 214 For vehicles repaired under warranty, use the table. Disclaimer Page 8988 Page 4440 Page 9893 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 11949 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. TheJ 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. TheJ 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. IfJ 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 4555 10. Remove the PIM cover retaining bolts (1). 11. Remove the PIM cover (2). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 12. Install the HV dc APM terminal fasteners (1) utilizing a magnetic socket. Tighten the terminal fasteners to 9 Nm (80 lb in) . Page 13020 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1545 Fuel Pump and Sender Assembly - Front (MEX) Page 7346 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit OnStar(R) - Destination Download Incomplete/Intermittent Global Positioning System: All Technical Service Bulletins OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 20054 Page 6447 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 17817 Carpet: Service and Repair Body Rear Inner Panel Carpet Replacement Body Rear Inner Panel Carpet Replacement Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 88861431 (Canadian P/N 88861436), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: Service and Repair Parking Assist Warning Indicator: Service and Repair Information Center Telltale Assembly Replacement Page 18843 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Page 15644 Disclaimer Page 6696 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Powertrain Component Views Left Side of the Engine Components (Diesel) Exhaust System - Exhaust Leak/Rattle/Rumble/Noises Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Exhaust Leak/Rattle/Rumble/Noises TECHNICAL Bulletin No.: 10-06-05-003A Date: February 04, 2011 Subject: Exhaust Leak, Rattle, Rumble and/or Noise (Install New Clamp and Align Correctly) Models: 2009-2011 Cadillac Escalade Hybrid 2009-2011 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe, Tahoe Hybrid 2009-2011 GMC Sierra 1500, Yukon, Yukon Hybrid, Yukon XL Equipped with 4.3L, 4.8L, 5.3L or 6.0L Engine 2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2011 Chevrolet Avalanche, Silverado, Suburban 2011 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL, Yukon Denali XL All Equipped with 6.2L Engine Supercede: This bulletin is being revised to add Parts Information. Please discard Corporate Bulletin Number 10-06-05-003 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an exhaust leak or noise. The noise may be described as a rattle or rumble. Cause This condition may be caused by an unseated pipe to pipe mid-joint connection as shown below. Correction Note Ensure that the pipe flares remain fully seated to each other while tightening the clamp. 1. Remove and discard the exhaust band (Norma) clamp. 2. Install and position a new exhaust band (Norma) clamp to the pipe joint. 3. Firmly push and maintain the pipes together while tightening the exhaust band (Norma) clamp bolt. Tighten Tighten the clamp bolt to 28 Nm (21 lb ft). Note After the clamp is installed, it does not need to be perpendicular to the pipe. It is acceptable to have a pipe to pipe or clamp angle. 4. Confirm that the clamp edges (both sides and all the way around the clamp) are fully seated on the pipe. 5. Run the engine and inspect the clamp joint to ensure there are no leaks and to ensure that the condition is corrected. Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 4972 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 5599 Engine Control Module (ECM) X2 (4.3L) MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Page 6877 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Page 6122 Camshaft Position (CMP) Sensor (Diesel) Page 12984 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 11246 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 2840 Junction Block - Left I/P X7 (JF4) A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Clutch: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 6183 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 11699 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 14838 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 1135 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Alarm Sensor - Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Alarm Sensor - Right Rear Middle (UD7) 8 - Marker Lamp - Tailgate (R05) 9 - Object Alarm Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Alarm Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 - Backup Lamp - Left Rear Rear of the Vehicle Components (Z88) Page 13051 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Behind the Grill Components - 1 of 2 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor (CJ2/C67) Behind the Grill Components - 2 of 2 Page 8799 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 797 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 2974 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6219 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 8473 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Page 18227 Page 12294 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 4176 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 2739 Junction Block - Rear Lamps X2 Locations Four Wheel Drive Selector Switch: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Audio - Information on USB/Multimedia Player Auxiliary Input / Output Jack: Technical Service Bulletins Audio - Information on USB/Multimedia Player INFORMATION Bulletin No.: 10-08-44-004A Date: November 11, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2011 Buick Regal 2010-2011 Cadillac SRX 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2011 Chevrolet Cruze, Equinox, Volt 2010-2011 GMC Terrain All Equipped with Convenience and Connectivity Package (RPOs UUK, UUL, UYS) Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 10-08-44-004 (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The universal serial bus (USB) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod(R)/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices 1. Verify the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and re-insert the iPod to verify the customer concern. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod nano(R) and iPod classic(R), toggle the Hold switch on and off (slide it to Hold, then turn it off again). Press and hold the Menu and Center (Select) buttons simultaneously until the Apple(R) logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod touch(R) and iPhone(R): Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. For iPod touch and iPhone: To obtain full use capabilities of their device, it needs to be fully powered up when connecting to the USB port. If these devices are fully powered down or in "sleep" mode, please advise the customer to press and hold the Sleep/Wake button on the top of the device for a few seconds and if an unlock pass code is required, to enter the pass code as well as slide the lower "Unlock" slider. 6. Have the customer inspect their cable for quality. Page 7143 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Heated Seats Description and Operation Seat Heater: Description and Operation Heated Seats Description and Operation Heated Seats Description and Operation Heated Seat Components The driver and passenger heated seat system consists of the following components: * Heated seat switch * Door lock/window switch * Memory seat module * Seat cushion heating element * Seat back heating element * Seat cushion temperature sensor * Seat back temperature sensor Modes of Operation The heated seat module (MSM) controls heated seat operation for both the driver and passenger seats. There are 2 modes of operation available for heated seats; both the seat cushion and seat back heat, or seat back only heat. When a heated seat temperature signal request is received, the MSM will activate both the seat cushion and seat back heating elements. When the heated seat BACK ONLY mode button is pressed once the MSM will deactivate the seat cushion heating element and leave the seat back heating element ON. Heated Seat Switch/LED Indicators and System Operation The left and right heated seats are controlled by separate heated seat switches located in the door panels. Ground is supplied to the heated seat switches through the switch low reference circuits from their respective door lock/window switches. The door lock/window switches also control the heated seat switch heat mode and temperature indicators. The memory seat module (MSM) controls the heated seat operation for both, the left and right heated seats. The following describes the sequence of operation and how the MSM responds to each of the switch inputs. * High Temperature-When the heated seat switch is pressed once, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch indicating the high heat request. In response to this signal, the door lock/window switch applies a low current voltage through the 3 temperature indicator control circuits illuminating all 3 LEDs indicating the high temperature mode. The switch then sends a message via the GMLAN serial data line to the MSM indicating the heated seat request. The MSM then applies battery voltage through the heating element supply voltage circuit to the seat cushion and seat back heating elements. At the same time, it supplies a ground through the element low reference circuits to the seat heating elements. * Medium Temperature-When the switch is pressed a second time, the MSM sets the temperature level to medium heat. The door lock/window switch removes the voltage from the high temperature indicator leaving 2 LEDs illuminated indicating the medium temperature mode. * Low Temperature-When the switch is pressed a third time, the MSM sets the temperature level to low heat. The door lock/window switch removes the voltage from the medium temperature indicator leaving 1 LED illuminated indicating the low temperature mode. * System OFF State-When the switch is pressed a fourth time, the MSM removes the battery voltage and grounds from the heating elements. The door lock/window switch removes the voltage from the low temperature indicator, indicating the system OFF state. * Back Only Mode-When the heated seat is ON and the BACK ONLY mode button is pressed, ground is applied through the switch contacts and the heated seat back only mode signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a GMLAN message to the MSM indicating the back only mode request. The MSM then opens the ground path to the seat cushion heater element, leaving the seat back heater active. The door lock/window switch turns OFF the seat cushion/back mode indicator, then applies a low current voltage through the heated seat back only mode indicator control circuit illuminating the back only mode indicator. Temperature Regulation The heated seat system is designed to warm the seat cushion and seat back to 3 different temperature settings; High, MED, and Low. The memory seat module (MSM) monitors the seat temperature through the temperature sensor signal circuits and the temperature sensors (thermistor) that are located in the seat cushion and the seat back. The temperature sensors are variable resistors, their resistance varies as the temperature of the seat changes. When the temperature sensor resistance indicates to the MSM that the seat has reached the desired temperature, the module opens the ground path of the seat heating elements through the heated seat element control circuit. The module will then cycle the element control circuit open and closed in order to maintain the desired temperature. Load Management The electrical power management function is designed to monitor the vehicle electrical load and determine when the battery is potentially in a high discharge condition. The heated seat system is one of the vehicle loads that is subject to reduction during a battery discharge condition. For more information on load management refer toElectrical Power Management Description and Operation (See: Starting and Charging/Description and Operation) . Body - Incorrect Sun Visor Label Child Seat: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 327 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 5641 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 2918 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1864 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 2818 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 4498 Drive Motor Generator Battery Control Module X2 (HP2) Page 5294 4. Tighten the air cleaner outlet duct clamp (1) at the MAF/IAT sensor. Tighten the clamps to 4 Nm (35 lb in). 5. Install the radiator inlet hose clamp clip (2) to the air cleaner outlet duct (1). 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 20641 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 12318 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9836 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 5436 10. Remove the CMP sensor (1) and O-ring seal (2). Installation Procedure 1. Inspect the CMP O-ring seal (2) for cuts or damage. If the seal is not damaged, it may be reused. 2. Lubricate the O-ring seal with clean engine oil. 3. Install the O-ring seal onto the sensor. 4. Instal the CMP sensor (1) to the front cover. Page 989 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 3921 18. Install the brake booster vacuum hose to the intake manifold nipple. 19. Position the brake booster vacuum hose clamp at the intake manifold. 20. Secure the brake booster vacuum hose to the intake manifold. 21. Install NEW intake manifold gaskets (514) to the intake manifold. 22. Remove the covers from the cylinder head passages. Page 18046 Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Page 16681 Page 10027 Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 7333 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 1663 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 9302 Figure 9 1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen just like the TIS 2000 procedure described above. Figure 10 3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure 10. Make sure the Tech 2(R) is connected to the computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech 2(R) should start blinking and a line will start scrolling across the screen indicating it is communicating with your computer. Figure 11 Page 4220 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Endgate Torque Rod Replacement Tailgate Hinge: Service and Repair Endgate Torque Rod Replacement Endgate Torque Rod Replacement Page 7875 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4749 Drive Motor Generator Battery Control Module X3 (HP2) Page 18665 Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Page 18766 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 13504 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 19564 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 17154 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Page 15199 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 15775 Disclaimer Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 4L60-E / 4L65-E / 4L70-E Automatic Transmission Pan Removal ...................................................... ................................................................................................................................... 4.7 liters (5.0 quarts) Overhaul .................................................................................................................................. ......................................................... 10.6 liters (11.0 quarts) 300 mm Torque Converter Approximate Dry Fill ............................................................................................................................ ................................................................ 11.50 liters (12.1 quarts) 6L80 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 5.7 liters (6.0 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 6L90 AUTOMATIC TRANSMISSION Pan Removal ........................................................................... .............................................................................................................. 6.0 liters (6.3 quarts) Overhaul .............................................................................................................................................. ............................................... 9.9 liters (10.5 quarts) Complete Trans System .................................. .................................................................................................................................. 11.7 liters (12.4 quarts) 2ML70 AUTOMATIC TRANSMISSION Drain Plug Only ..................................................................... ........................................................................................................... 9.93 liters (10.5 quarts) Drop Pan and Filter ...................................................................................................................................... ................................... 10.88 liters (11.5 quarts) Dry Transmission (Empty) .............................................................................................................................................................. 12.30 liters (13.0 quarts) Locations Power Door Lock Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 15600 Page 20454 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 20561 Heated Glass Element: Testing and Inspection Rear Window Defogger Malfunction Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description When the rear defogger button is pressed, voltage is supplied to the relay coil by the HVAC control module which also illuminates the rear window defogger indicator. B+ voltage is supplied at all times to the relay switched input and the relay coil is always grounded. This allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the rear window defogger. Reference Information Schematic Reference Defogger Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Rear Window Defogger Description and Operation (See: Windows/Description and Operation/Rear Window Defogger Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, RPO CJ2, observe the scan tool Auto HVAC Rear Defrost Switch parameter while pressing the rear window defogger switch. The parameter should change between Active and Inactive. ‹› If the parameter does not change between the commanded states, replace the HVAC module. 2. RPO CJ3, observe the scan tool Manual HVAC Rear Defrost State parameter while pressing the rear window defogger switch. The parameter should change between On and Off. ‹› If the parameter does not change between the commanded states, replace the HVAC module. Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Page 13352 Junction Block - Left I/P X9 (except MEX) Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 5438 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 12606 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.8L and 5.3L) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (6.0L and 6.2L) Page 7983 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 15182 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2042 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Page 18940 Seat Latch: Service and Repair Rear Seat Latch Replacement (Crew Cab with A68) Rear Seat Latch Replacement (Crew Cab with A68) Page 13571 Junction Block - Right I/P X4 Page 13211 Page 8253 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 4287 Note The O-ring seal may be reused if not cut or damaged. 9. Inspect the O-ring seal (421) for cuts or damage, replace as necessary. 10. Lubricate the O-ring seal (421) with clean engine oil. 11. Install the oil level indicator tube (420) to the engine block. 12. Install the oil level indicator tube bolt (419). Tighten the bolt 25 Nm (18 lb ft). 13. Install the spark plug wires (1) to the spark plugs. 14. Install the spark plug wires to the ignition coils. 15. Inspect the spark plug wires for proper installation. 1. Push sideways on each boot in order to inspect the seating. Page 19594 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7570 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Diagrams Marker Lamp: Diagrams Component Connector End Views Marker Lamp - Left Front (Z88) Marker Lamp - Left Rear (Z88) Marker Lamp - Right Front (Z88) Page 12200 Page 11824 Page 3020 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 7680 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 19939 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12636 X212 Instrument Panel Harness to Instrument Panel Extension Harness (Early Production Except Y91/MEX/HP2/8S8) Page 19271 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 4267 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Page 3782 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Lower the differential carrier. 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. 15. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Remove the oil cooler hose bracket bolt. (1) 2. Remove the oil cooler hose adapter bolts. (2) 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. Installation Procedure Wheels/Tires - Module Programming For 20/22 Inch Wheels PROM - Programmable Read Only Memory: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 11481 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 5818 issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference * Component Connector End Views (See: Diagrams/Connector Views) * Splice Pack Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Circuit/System Testing Note Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module locations on the low speed GMLAN serial data circuit * Each control module's low speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the low speed GMLAN serial data circuit, refer toData Link References (See: Initial Inspection and Diagnostic Overview/Data Link References) . Communications should not be available with two or more control modules on the low speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only, refer toDTC U0100-U0299 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100) . ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 1 and ground. ‹› If greater than the specified range, test the serial data circuit for a short to voltage, refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 1 and ground. Page 18864 Seat Heater: Connector Views Component Connector End Views Heated Seat Element - Driver Back (AN3 without KB6) Heated Seat Element - Driver Cushion (AN3 without KB6) Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17902 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Crew Cab) Rear Side Door Sill Trim Plate Replacement (Crew Cab) Page 8092 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 2269 4. Loosen the air cleaner outlet duct clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 5. Loosen the air cleaner outlet duct clamp (2) at the throttle body. 6. Lift up the air cleaner outlet duct at the resonator tab in order to separate the resonator from the stud on the intake manifold. 7. Remove the air cleaner outlet duct (3) from the throttle body and MAF/IAT sensor. Installation Procedure Note Ensure that the notch in the air cleaner outlet duct throttle body aligns with the boss on top of the throttle body. 1. Install the air cleaner outlet duct (3) to the throttle body and MAF/IAT sensor. Ensure that the resonator tab aligns with the stud on the intake manifold. 2. Push down on the air cleaner outlet duct resonator directly over the resonator tab in order to secure the resonator to the stud on the intake manifold. 3. Tighten the air cleaner outlet duct clamp (2) at the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Page 16943 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 1418 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 12302 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 10373 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2820 Fuse Block - Auxiliary (HP2), Bottom View Page 10080 Seals and Gaskets: Service and Repair MP 3023/3024-NQH - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Page 5354 3. Loosen the MAF/IAT sensor adapter clamp. 4. Remove the MAF/IAT sensor from the air cleaner assembly. Installation Procedure Note The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Tighten the MAF/IAT sensor adapter clamp to 4 Nm (35 lb in) . 3. Connect the engine wiring harness electrical connector (2) to the MAF/IAT sensor (1). 4. Install the air cleaner outlet resonator. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Locations Fuse Block: Locations Harness Routing Views Driver Door Harness Routing 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Passenger Door Harness Routing Page 17265 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement Front Bumper Impact Bar Extension Replacement Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13437 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 20239 Page 20947 6. Disconnect the electrical connectors. 7. Lower the vehicle in order to access the hood latch. 8. Open the hood. 9. Remove the windshield washer solvent cap. 10. Remove the auxiliary battery tray, if equipped. Refer to Auxiliary Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Auxiliary Battery Tray Replacement) . Note Remove the washer container from the underside of the vehicle through the wheelhouse opening. 11. Remove the upper windshield washer solvent container bolts. 12. Remove the windshield washer solvent container assembly (2). 13. Drain the windshield washer solvent into a suitable clean container. Installation Procedure Page 13885 Page 9515 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half ofJ 36652-1 orJ 36652-2 . Page 18886 ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 16. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 17. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower motor control circuit terminal 2 * Seat back blower motor speed control terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 18. If all circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. Component Testing Heated and Cooled Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the low reference circuit terminal 4 and the signal terminals listed below the with the switch in the open position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If not the specified value, replace the heated and cooled seat switch. 3. Test for less than 2 Ω between the low reference circuit terminal 4 and the signal terminals listed below with the appropriate switch in the closed position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If greater than the specified range, replace the heated and cooled seat switch. 4. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 5. Connect a test lamp between B+ and each control terminal listed below. The appropriate indicator should illuminate. * Seat back only mode indicator terminal 11 * Seat cool mode indicator terminal 12 * Seat back and cushion indicator terminal 10 * Low temperature indicator terminal 9 * Medium temperature indicator terminal 1 Page 7196 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 15986 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended/Crew Cab with ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Page 13550 Page 11724 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 13062 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 6059 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 11778 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 7411 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Front Half 7 - Transfer Case Half Locating Pin 7 - Transfer Case Half Locating Pin 8 - Transfer Case Input Shaft Bearing Assembly 9 - Transfer Case Input Shaft Inner Retaining Ring 10 - Transfer Case High/Low Internal Gear 11 Transfer Case High/Low Internal Gear Retaining Ring 12 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 13 - Vehicle Speed Sensor Assembly 14 - Vehicle Speed Sensor O-Ring - Seal 15 - Transfer Case Rear Half 16 - Transfer Case Access Hole Plug 17 - Transfer Case - Harness - Bracket 18 - Transfer Case Half Bolt/Screw 19 - Transfer Case Rear Output Shaft Bushing 20 - Transfer Case Rear Output Shaft Seal 21 - Transfer Case Actuator Shaft Position Sensor Bolt/Screw 22 - Transfer Case Actuator Shaft Position Sensor Assembly 23 - Transfer Case Actuator Shaft Position Sensor - O-Ring - Seal 24 - Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw 25 - Transfer Case Two/Four Wheel Drive Actuator Assembly 26 - Transfer Case Two/Four Wheel Drive Actuator Seal 27 - Transfer Case Oil Drain Plug 28 - Transfer Case Oil Fill Plug 29 - Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly 30 Transfer Case Four Wheel Drive Actuator Lever Shaft Bearing Assembly Internal Components Page 13613 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 4114 Page 5224 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 4794 Body Control Module (BCM) X4 Page 19511 Harness Components Page 17476 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can Page 5043 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 6961 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 13229 Junction Block - Left I/P X9 (except MEX) Page 8756 Page 9869 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 3935 Important: For proper orientation, note the installation direction of the oil seal. The oil seal is a reverse-lip design. The part number is applied to the outside face of the seal, as shown. 1. Inspect the seal and identify the part number markings for proper orientation. 2. Install the J 41479 cone (2) and bolts onto the rear of the crankshaft. 3. Tighten the bolts until snug. Do not overtighten. 4. Install the rear oil seal onto the tapered cone (2) and push the seal to the rear seal bore. Install the oil seal with the part number markings facing away from the engine. 5. Thread the J 41479 threaded rod into the tapered cone until the tool (1) contacts the oil seal. 6. Align the oil seal into the tool (1). 7. Rotate the handle of the tool (1) clockwise until the seal enters the rear cover and bottoms into the cover bore. 8. Remove the J 41479 . 9. Install the automatic transmission flexplate, refer to Automatic Transmission Flex Plate Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair) . Page 16348 Page 20488 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 11875 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 3599 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 5399 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 3021 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 19401 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 9379 6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft. 7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft. 8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7. This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 . 9. Using a micrometer, measure the thickness of the J 34673 . 10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8. This is the shim thickness for the front axle without having any axle shaft endplay. 11. The correct shim size will be one size smaller than the figure obtained in the previous step. Note the following examples: * If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim. * If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim. Alternate Adjustment Method Note Use this method only if the proper tools for calculating the shim size are unavailable. 1. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place. 2. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the bolts and tighten to 40 Nm (30 lb ft) . 4. Measure the shaft end play using the following procedure: 1. Install the J 8001 or the equivalent on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange. Page 1779 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 12485 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 15036 Compressor Clutch: Adjustments Air Conditioning Clutch Drive Plate Adjustment 1. Install the clutch plate assembly. Note Ensure the drive plate does not drag against the pulley when the pulley is rotated. 2. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the clutch plate retaining bolt and tighten to 18 Nm (13 lb ft) . Page 20774 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Page 1938 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 10908 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 2648 Fuse Block - Underhood X5 Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Page 12683 Page 15866 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 3039 Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 2927 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 18120 For vehicles repaired under warranty, use the table. Disclaimer Page 10215 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 11637 Switches and Relays Page 4678 Note The gray side tabs on the accessory dc power control module (APM) assembly connector (2) must be pressed in before rotating the lever. 20. Disconnect the APM assembly connector (2) using the following procedure: 1. Push the green tab. 2. Squeeze the gray side tabs, then rotate the lever. 21. Disconnect the APM assembly connector (3) using the following procedure: 1. Remove the locking tab. 2. Insert a small flat blade screwdriver into the locking tab area and raise the tab while pulling on the connector. 22. Disconnect the remaining APM assembly connector (1). Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Front Bumper Impact Bar Replacement (Chevrolet) Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement (Chevrolet) Front Bumper Impact Bar Replacement (Chevrolet) Page 14283 sealed. Fluid trapped in this area during assembly may seep from the adjuster plug. The rack should not be replaced for this condition. - You can distinguish seepage from an active leak by removing the left tie rod boot clamp and inspecting for the presence of fluid at the inner tie rod. - If no fluid is found in the left tie rod boot, replace the boot clamp and clean the seepage from the rack. No further action is needed. - If fluid is found in the left tie rod boot, replace the gear assembly. Warranty Information For vehicles repaired under warranty please refer to the Labor Time Guide and claim the applicable Labor Operation for the repaired or replaced component. Disclaimer Page 17561 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 Nm (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module . 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Tighten bolt to 11 Nm (97 lb in). 6. Install the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair) . 7. Inspect the rear sliding window for proper operation. Page 3957 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 20466 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Page 11329 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J-26889 - Compressor over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). Page 9057 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 2677 Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 1955 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Page 20491 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 2631 Page 7197 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 5607 Engine Control Module (ECM) X2 (Diesel) Page 11894 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Page 969 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10283 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 16826 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 15407 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Page 16806 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 8132 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 14421 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 20828 Page 17479 Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Page 1692 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 12088 Fuse Block - Underhood X8 (Chassis Harness) (JL1) Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 7249 Switch Position Icons Page 2836 Page 11094 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the EBCM bolts (1) and tighten in a cross pattern to 3 Nm (27 lb in) . 3. Install the sleeves and insulators to the BPMV, if removed. 4. Install the BPMV assembly to the bracket (1). Page 11398 Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Page 1768 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 4391 2. Install the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement) . 3. Install the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (With Cab Chassis) (See: Catalytic Converter/Service and Repair) . Page 13383 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Instrument Panel/Center Console Component Views Behind the I/P Components Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 12858 For vehicles repaired under warranty, use the table. Disclaimer Page 13249 Junction Block - Rear Lamps X2 Page 10654 Page 8288 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 9666 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 459 Page 12744 X303 Body Harness to Driver Seat Harness (Except AN3/MEX) X303 Driver Seat Harness to Body Harness (MEX/A52) Page 14808 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 3444 6. Inspect the sprockets for proper alignment. The mark on the CMP actuator sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. 7. Remove the EN 46330 . Page 13191 Fuse Block - Underhood X1 Page 20463 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 2929 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 3110 Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 17031 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Alarm Sensor - Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Alarm Sensor - Right Rear Middle (UD7) 8 - Marker Lamp - Tailgate (R05) 9 - Object Alarm Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Alarm Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 - Backup Lamp - Left Rear Rear of the Vehicle Components (Z88) Page 19561 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1929 Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 6778 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 13777 Page 19802 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in) . 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Instrument Panel Electrical Center or Junction Block Replacement - Left Side) . 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . Page 7367 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 11003 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection) . 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer toSymptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes) . Pressure Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent . Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter . 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. Page 8663 For vehicles repaired under warranty, use the table. Disclaimer Page 12987 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8762 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 5957 Auxiliary Body Control Module (XBCM) X1 (EXP) Page 8291 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5755 Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 9052 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 17436 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2661 Page 12028 Page 3958 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Locations Parking Brake Release Switch: Locations Below the Left of the I/P Components - 1 of 2 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Below the Left of the I/P Components - 2 of 2 Page 18862 Page 20585 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps -Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut -Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Page 3345 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 9790 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 13626 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Page 17890 Page 11837 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 16204 Disclaimer Page 17119 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control module electrical connector. Note It is not necessary to completely remove the bolts. 4. Reach above the trailer brake control module and relay bracket and loosen, but do not remove, the trailer brake control module bolts (1). Page 19043 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (AN3/DL3) Page 19609 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 75 Disclaimer Page 343 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7897 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 12993 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 10818 Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 8171 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 12511 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 2121 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 10174 Switches and Relays Page 849 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 - G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Accessories - Pick Up Box Accessory Mounting Information Truck Bed Storage Compartment: Technical Service Bulletins Accessories - Pick Up Box Accessory Mounting Information INFORMATION Bulletin No.: 09-08-66-011A Date: October 04, 2010 Subject: Information on Mounting Points for Pickup Box Accessories Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-011 (08 - Body and Accessories). The pickup box was designed for the use of add-on equipment. However there are specific mounting points that must be used along with weight restrictions, refer to the following: Chart 1 - Weight Restrictions for Pickup Box Add-Ons. Structural members have been added to provide load paths directly to the platform cross-sills and into the vehicle frame. Aftermarket accessories should take advantage of these intended load paths as detailed below in Figures 1-4. Depending on the accessory design, it may be necessary to add some form of a spacer under the accessories at the structural hard points to take up any gap. Do not use the GM Cargo Management Option mounting points for attaching anything other than the GM Cargo Management system as referenced in Figure 5. Figure 1 - Side View - Structural Members Figure 2 - Top View - Structural Members Figure 3 - Top View - Front Structure Page 12929 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Page 10300 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Page 10825 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) . 2. Drain all the brake fluid from the caliper. Note The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 7957 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 12154 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Restraints/Interior - Front Seat Belt Twisted Seat Belt: Customer Interest Restraints/Interior - Front Seat Belt Twisted TECHNICAL Bulletin No.: 07-09-40-001A Date: May 14, 2009 Subject: Front Seatbelt Latch Plate Reversed, Front Seatbelt Twisted (Perform Repair to Untwist Seatbelt) Models: 2008-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 Saturn OUTLOOK .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the Traverse model and the 2009 model year. Please discard Corporate Bulletin Number 07-09-40-001 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the seatbelt latch plate is reversed on the belt webbing or that they have to twist the webbing before buckling the seatbelt. This condition can be visually verified by inspecting the location of the latch plate tongue. If the tongue is between the webbing and the pillar post, it is reversed. Correction Do NOT replace the seatbelt retractor for this condition. To correct this condition, perform the following repair. 1. Pull the majority of the belt webbing out of the retractor. 2. With the latch plate resting at its lowest point, take the webbing above the latch plate and fold the webbing over itself at a 45 degree angle. Pinch the folded portion between the thumb and forefinger. 3. Using the other hand, pull the latch plate up over the fold until past the doubled over section. Page 14460 Ball Joint: Technical Service Bulletins Suspension - Revised Front Lower Ball Joint Nut Torque INFORMATION Bulletin No.: 09-03-08-001A Date: March 17, 2009 Subject: Revised Front Lower Ball Joint Nut Service Procedure Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to change information on the lower ball joint nut. Please discard Corporate Bulletin Number 09-03-08-001 (03 - Suspension). For service, GM P/N 15046285 is the current nut to use. Tighten the nut to 125 Nm (92 lb ft). Disclaimer Page 3699 Note DO NOT raise and/or support the engine by the crankshaft balancer or oil pan. 7. Place an adjustable (screw type) jack to the tab (1) located on the engine block. 8. Working through the wheelhouse opening, remove the engine mount to engine bolts (1). 9. Using the adjustable jack, raise the engine slightly until there is enough clearance to remove the engine mount. Page 1624 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressorJ 23653-SIR and adapterJ 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 7214 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 5880 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 7503 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Hybrid - Reinstalling Hybrid Transmission Drive Motors Wiring Harness: All Technical Service Bulletins Hybrid - Reinstalling Hybrid Transmission Drive Motors INFORMATION Bulletin No.: 10-06-122-001 Date: November 03, 2010 Subject: Reinstalling Hybrid Transmission Drive Motors On 2-Mode Hybrid Full Size Trucks Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with 2ML70 Hybrid Transmission (RPO M99) All Built Prior to VIN Breakpoint 10020698 During service of a 2-Mode hybrid drive motor, the motor harness can easily be damaged if the appropriate precautions are not used. When reinstalling a drive motor, sharp edges of the transmission case access opening may chafe or cut the harness when the drive motor is fed through the case opening. Recommendation Use the procedure and parts below to protect the drive motor harness PRIOR to reinstallation into the transmission case. 1. Remove the black plastic wiring harness clip (1) from the motor casing and pull the harness out of the clip, exposing the drive motor wires (2). Page 12525 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 4246 required. 1. Start the engine with the gear selector in PARK. 2. Wait until the Audio or Caution Screen is displayed after the opening screen has appeared. 3. Press the: NAV hard key. Note If the Caution Screen is displayed at Step 4 then follow the instruction, otherwise proceed to Step 5. 4. Press the: I AGREE soft key. 5. Press the: MENU hard key. 6. Press the: NAV soft key. 7. Press the: MAP DATABASE INFORMATION soft key. 8. Press the: CHANGE soft key. 9. The navigation radio will automatically eject the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 10. Load the update disc into the slot behind the display screen by inserting it partially until the system pulls it in. 11. The screen: Preparing to Load System Software, will be displayed while the update is loading. The update should take approximately 4-6 minutes. Observe the progress bar as it will indicate the progress of the update. 12. AFTER the system restarts, press the: EJECT soft key to eject the software update disc. The disc may be used again on another vehicle. 13. Load the map DVD into the SAME slot located behind the display screen. DO NOT put it in the top slot. 14. Press the: CLOSE soft key. 15. After the map screen is displayed, touch the map screen to confirm it can be scrolled. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Drive the vehicle to an OUTDOOR location with an open view to the sky, away from any tall buildings. 16. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 17. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 18. Verify that the Destination search area is properly displayed. 1. Press the: DESTINATION hard key. 2. Press the: CHANGE SEARCH AREA soft key. 3. Select the: correct area for the vehicle's location. Parts Information Navigation software update discs are for the dealer to update the navigation radio software only. They DO NOT update or replace the navigation map data that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. Navigation software discs may be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 4240 For vehicles repaired under warranty, use the table. Disclaimer Page 7830 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Procedures Hydraulic Fluid Accumulator: Procedures Power Brake Booster Pump Fluid Accumulator Disposal Page 6793 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 19395 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 18948 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Page 18769 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 15615 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 10443 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 19698 Fuel Pump and Sender Assembly - Front (MEX) Page 18931 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (AN3/DL3) Page 2729 Junction Block - Right I/P X2 OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 13992 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 10334 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 19279 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Page 4797 Body Control Module (BCM) X6 Page 20367 Page 4684 Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 22. Clean the sealing surface of the 3 phase cable cover as necessary. 23. Position the 3 phase cable cover (2) onto the PIM distribution box ensuring the seal remains in place. 24. Tighten the 3 phase cable cover fasteners (1). Tighten the fasteners to 9 Nm (80 lb in) . 25. Connect the drive motor generator control module assembly connector (1). 26. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . 27. Install the sight shield. Refer to Drive Motor Generator Control Module Sight Shield Replacement (See: Drive Motor Generator Control Module Sight Shield Replacement) . 28. Install the fender cross brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 29. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . 30. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 31. For control module programming and setup procedures, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 3632 * Pull only on the boot in order to remove the wire from the ignition coil. 7. Remove the ignition coil bracket studs (720). 8. Remove the ignition coil bracket (719). 9. Remove the positive crankcase ventilation (PCV) hose. 10. Loosen the valve rocker arm cover bolts. 11. Remove the valve rocker arm cover. Page 541 Page 19388 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 4617 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 12087 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Diagrams Clearance Lamp: Diagrams Component Connector End Views Rear Fender Clearance Lamp - Left Front (RO5) Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 333 Page 8523 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Specifications Water Pump: Specifications Water Pump Bolts - First Pass............................................................................................................. ............................................................15 Nm (11 lb ft) Water Pump Bolts - Final Pass....................... .................................................................................................................................................30 Nm (22 lb ft) Page 7258 Page 8257 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13197 Page 20584 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Passenger Compartment/Roof Component Views Overhead Console Components Page 312 Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 967 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18819 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 12629 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (Except Y91) to Headliner Harness (UE1/U3U/UVB) Page 12601 X109 Engine Harness to Instrument Panel Harness (Late Production with 4.8L/5.3L/6.0L/6.2L Except NQF/NQH/HP2) Page 19389 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 3035 Fuse Holder X2 (Generator Harness) (Gas with 9L4 except 4.3L) Fuse Holder X2 (Engine Chassis Harness) (Diesel) Fuse Holder X3 (Battery Positive Harness) (9L4) Fuse Holder X3 (Engine Harness) (Diesel) Fuse Holder X4 (Auxiliary Battery Harness) (TP2) Page 19840 Customer TPMS Information Page 5660 Page 10239 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 18918 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heatng and Cooling Module - Passenger (KB6) Page 12457 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 20137 Page 7728 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 14405 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 10560 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 9009 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Drive Belt Replacement Drive Belt: Service and Repair Drive Belt Replacement Drive Belt Replacement Removal Procedure 1. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Install a breaker bar with hex-head socket to the drive belt tensioner bolt. 3. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt. 4. Remove the belt (1) from the pulleys and the drive belt tensioner (2). 5. Slowly release the tension on the drive belt tensioner. 6. Remove the breaker bar and socket from the drive belt tensioner bolt. 7. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure Page 9084 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 13829 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 8051 Switches and Relays Page 14851 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 317 Memory Seat Module (MSM) X5 (AN3) Page 16146 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13589 Page 17160 Trailer Brake Control Relay (JL1) Trailer Brake Control Switch (JL1) Page 153 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 15395 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 20432 Devices and Sensors Page 8576 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 5738 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3090 Fuse Block - I/P Top View Page 15384 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2/C67) Locations Timing Component Alignment Marks: Locations Inspect the sprockets for proper alignment. The mark on the CMP (1) actuator sprocket should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position. Page 4464 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 9810 Disclaimer Page 8498 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. Page 10257 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Note TPA is keyed and can only be inserted in one direction. Page 6040 Page 7007 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer toSIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations) . There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) orElectrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . Page 9584 Drive/Propeller Shaft: Service and Repair Propeller Shaft Slip Yoke Boot Replacement Propeller Shaft Slip Yoke Boot Replacement Page 12247 Junction Block - Right I/P X3 Page 13173 Fuse Block - Auxiliary (HP2), Top View Page 11430 Page 12742 Page 2637 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 17724 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in) . 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . Page 4937 Page 2720 Junction Block - Left I/P X10 (except MEX) Page 1876 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas Except HP2) Page 1533 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 2053 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 1751 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 3920 13. Lubricate the MAP sensor seal with clean engine oil. 14. Install the MAP sensor. 15. Install the MAP sensor retainer. 16. Install the upper intake manifold cover. 17. Install the upper intake manifold cover nut until snug Page 18723 Seat Heater: Locations Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 1 - Seat Recline Motor -Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor -Driver (AN3) 3 - Seat Lumbar Vertical Motor -Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor -Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor -Driver (AN3) 7 - Seat Recline Position Sensor -Driver (AN3) 8 - Seat Lumbar Switch -Driver (AN3) 9 - Seat Adjuster Switch -Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) Page 11603 6. Ensure that the junction block retainers are in the open position (1). 7. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 8. Install the underhood junction block cover. Page 10095 Page 20624 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) Page 12977 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12406 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 12307 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Page 14760 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 2027 1 - Brake Master Cylinder Piston Position Sensor 2 - Brake Fluid Level Switch 3 - Fuse Block Underhood 4 - Battery 5 - Engine Control Module (ECM) 6 - Fuse Block - Auxiliary 7 - Battery Current Sensor 8 - Windshield Wiper Motor Rear of the Engine Compartment Components Page 7949 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 13784 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Page 20472 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3414 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 11222 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 20271 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 10009 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Service and Repair Ash Tray: Service and Repair Ashtray Replacement Locations Oxygen Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 18883 ‹› If less than the specified range, test for a short between the appropriate control circuits. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. ‹› If greater than the specified range, test the appropriate control circuits for an open/high resistance. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. 6. Connect the X1, X2, X3 harness connectors at the CCSM. 7. Disconnect the harness connector at the seat cushion heat/cool seat ventilation blower. 8. Test for less than 5 Ω between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 9. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 10. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 11. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat cushion blower motor control terminal 2 * Seat cushion blower motor speed control terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 12. Ignition OFF, connect the harness connector to the seat cushion heat/cool seat ventilation blower. 13. Disconnect the harness connector at the seat back heat/cool seat ventilation blower. 14. Test for less than 5 Ω between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 15. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 16. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. Page 6763 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended Cab With 8 Ft Bed Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) Removal Procedure Note Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to theFuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) . 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Page 3859 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 14862 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . 4. Remove the wheel stud from the hub flange using the J 43631 . 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange . 4. Tighten the lug nut until the stud contacts the back of the hub flange. Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair)Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) Page 8536 Connector Cross Reference Tables Follow the tables below to determine the correct pin-out from the original harness connector to the replacement service pigtail connector. Parts Information Disclaimer Locations Blower Motor: Locations Instrument Panel/Center Console Component Views Behind the I/P Components 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 with YE9) 6 - Digital Radio Receiver (U2K) Behind the I/P Components (9L4) Page 6198 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 2800 Page 14424 Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch - Left (K34/KA9) 6 - Heated Steering Wheel (KA9) Page 9443 6. Remove the key. 7. Using the J 2222-C - wrench , and loosen the adjusting nut. 8. Remove the adjusting nut. Note If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . Page 4382 5. Install the insulator (1) to the intermediate muffler assembly hanger. 6. If equipped with a 5.3L, or a 6.0L engine, perform the following steps. 7. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. 8. With the aid of an assistant, position and install the muffler assembly. 9. Install the insulators (1, 2) to the front and rear muffler assembly hangers. Page 7067 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 3849 10. Connect the engine harness electrical connector (1) to the oil level sensor. 11. For both the 1500 and 2500 series, perform the following steps prior to installing the crossbar bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with denatured alcohol or equivalent and allow to dry. 3. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the bolt threads. 12. For 2500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 120 Nm (89 lb ft). Page 7341 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 778 Left Rear Frame Rail (20/30 Series) 1 - Trailer Connector (except MEX/EXP) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Brake Control Relay (JL1) Rear Frame and Underbody Components (31 Series) Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 3. Remove the wheel drive shaft, if equipped. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement) . 4. Remove the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) ()Front Wheel Hub, Bearing, and Seal Replacement (1500) (See: Suspension/Wheel Hub/Service and Repair) . 5. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Inner Tie Rod Replacement) . 6. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Suspension/Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Suspension/Control Arm/Service and Repair/Upper Control Arm Replacement) . 7. Separate the lower control arm from the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Suspension/Control Arm/Service and Repair/Lower Control Arm Replacement) . 8. Remove the knuckle from the vehicle. Installation Procedure Page 11695 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 594 Page 2332 3. Slide the belt installation tool (1) upward, installing the belt (2) onto the belt installation tool. 4. Slide the belt installation tool downward, positioning the belt onto the A/C pulley, applying light tension to the belt. 5. Position the lower portion of the belt (1) with the ribbed area facing forward. Page 4383 10. Install the insulator (1) to the intermediate muffler assembly hanger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 11. Install the catalytic converter to exhaust muffler nuts and tighten to 45 Nm (33 lb ft) . 12. Return the spare tire to the original position. 13. Lower the vehicle. Page 6270 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (6.0L with ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (4.3L) Page 10236 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7905 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 13727 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Page 12308 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 11167 Disclaimer Page 5146 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 3789 Important: Do not manually depress the retaining clip when installing the plastic cap. 6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Page 19970 Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Page 6795 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Page 12583 1 - Door Frame 2 - X700 Right Rear Door Harness Routing (Extended Cab) Page 11268 Tools Required J 37043 Park Brake Cable Release Tool Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling) . 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable from the cable guides. 7. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair) . 8. Using the J 37043 (1), remove the park brake cable from the backing plate. Page 16313 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Page 10827 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Page 6126 5. Working through the crankshaft balancer opening, loosen the CMP sensor wire harness bolt (1) 2 turns using a box wrench. 6. Remove the 2 remaining CMP sensor wire harness bolts (1). Page 13109 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 12380 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 8344 For vehicles repaired under warranty, use the table. Disclaimer Page 16215 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 12980 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Front Seat Heater Control Module Replacement Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Front Seat Heater Control Module Replacement Page 16152 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 719 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Page 15962 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Page 11839 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 18232 Memory Seat Module (MSM) X4 (AN3) Page 4690 16. Install a new PIM cover seal (3). Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 17. Clean the sealing surface of the PIM cover as necessary. 18. Position the PIM cover (2) onto the PIM ensuring the seal remains in place. 19. Install the PIM cover fasteners (1). Tighten the fasteners to 5 Nm (44 lb in) . Page 18271 Trailer Brake Control Module (JL1 with 31 Series) Page 7971 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 743 Page 263 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 6046 Page 6970 Crankshaft Position (CKP) Sensor (Diesel) A/T - Hybrid Transmissions Service Auxiliary Fluid Pump Control Module: All Technical Service Bulletins A/T - Hybrid Transmissions Service Auxiliary Fluid Pump INFORMATION Bulletin No.: 10-07-30-009 Date: June 09, 2010 Subject: Information on Hybrid Service Transmissions and Auxiliary Fluid Pump/Control Module Connector Compatibility Models: 2008-2009 Cadillac Escalade Hybrid 2008-2009 Chevrolet Tahoe Hybrid 2009 Chevrolet Silverado Hybrid 2008-2009 GMC Yukon Hybrid 2009 GMC Sierra Hybrid All Equipped with Hybrid Propulsion RPO HP2 Please Refer to GMVIS Hybrid Service Transmissions/Auxiliary Fluid Pump New hybrid service transmissions include a 2010 model year transmission auxiliary fluid pump that utilizes an updated connector that will not plug into the transmission auxiliary fluid pump control module. This includes the following service transmission part numbers: - 2008 2WD - P/N 24256371 - 2008 4WD - P/N 24256372 - 2009 2WD - P/N 24256375 - 2009 4WD - P/N 24256376 The 2010 transmission auxiliary fluid pump, P/N 19207983, has a different connector that does not match previous model year service transmissions. Internally, the 2010 auxiliary fluid pump is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump control module utilizing a replacement service connector on the control module. The 2008-2009 transmission auxiliary fluid pump service part will be replaced by the 2010 version and will be required to service 2008-2009 model year vehicles. Service replacement for these vehicles will also require a replacement service connector to interface with a 2008-2009 transmission auxiliary fluid pump control module. Transmission Auxiliary Fluid Pump Control Module The 2008-2009 transmission auxiliary fluid pump control module service part will be replaced by the 2010 version and is required to service 2008-2009 model year vehicles. The 2010 transmission auxiliary fluid pump control module, P/N 29546636, includes different connectors that do not match previous model year transmission auxiliary fluid pumps and engine wiring harnesses. Internally, the 2010 auxiliary fluid pump control module is identical to the 2008-2009 pump and will interface with a 2008-2009 transmission auxiliary fluid pump and engine wiring harness utilizing replacement service connectors on the transmission auxiliary fluid pump and engine wiring harness. Instructions Follow the tables below when servicing 2008 and 2009 model year vehicles with the above hybrid service transmissions, 2010 transmission auxiliary fluid pumps and 2010 transmission auxiliary fluid pump control modules. Refer to Component Connector End Views, Hybrid Controls Schematics and Splicing Copper Wire Using Splice Sleeves in SI for additional information on these connectors, circuits and use of the splice sleeves included with the service connectors listed below. Important The connectors listed are standard "pigtail" type splice connectors with 406 mm (16 in) leads. When installing, cut the pigtail leads back to a length just long enough to install the splice connectors. When cutting off the original connector, cut the harness just behind the connector body. Performing these steps will insure the harness remains as close as possible to the original length. It is especially important to not cut beyond the sealed portion of the auxiliary fluid pump harness. Component to Connector Reference Table Follow the table below to determine the correct service connector to use based on the component replaced. Page 7918 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 5028 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Page 13573 Junction Block - Rear Lamps Electrical Center Identification Views Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 12384 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 1721 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Page 12677 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) 09-08-127-001 - END OF INFORMATION NEED Parking Assist Distance Sensor: All Technical Service Bulletins 09-08-127-001 - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-127-001B Date: August 10, 2009 Subject: EI09084 - Rear Parking Assist System Inoperative (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2009 Saturn OUTLOOK All Equipped with Rear Parking Assist (RPO UD7) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-127-001A (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 9524 Ensure that the outer bearing assembly rotates freely in the hub 5. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the wheel hub over and seat the outer bearing assembly against the retaining ring. 6. Turn the wheel hub over and install the inner bearing cup. 7. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 8. Install the inner bearing. Note Ensure the seal is fully seated in the hub bore. Page 3998 Timing Cover: Service and Repair Engine Front Cover Replacement Special Tools EN-48853 Front Cover Alignment Tool Removal Procedure 1. Remove the water pump. 2. Remove the crankshaft balancer. 3. Disconnect the camshaft position sensor wire harness electrical connector (1) from the CMP actuator magnet. 4. Disconnect the engine harness electrical connector (2) from the CMP sensor wire harness electrical connector. 5. Remove the oil pan-to-front cover bolts (1). Page 9579 7. Reference mark the transmission or transfer case (1), output shaft flange (2), universal joint bearing cap (3), and the propeller shaft. 8. Remove the center bearing support nuts (1). 9. Remove the center bearing support (2). Note For those vehicles equipped with the yoke attached to the output shaft, proceed to step 10. Those vehicles equipped with a slip yoke, proceed to step 12. 10. For vehicles equipped with the yoke attached to the output shaft, use a suitable jack stand support the propeller shaft until propeller shaft is to be removed. 11. Remove the propeller shaft bolts (3), the straps (4), and the propeller shaft (2) from the transmission or the transfer case (1). Page 19563 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 11827 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 19323 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair) . 3. Ensure that the sunroof does not have any air or waterleaks. Page 10192 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ω position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Special Tools J 39200 - Digital Multimeter (DMM) Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 MΩ or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) . * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Page 18795 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7712 Harness Components Page 19643 Locations Driver/Vehicle Information Display: Locations Instrument Panel/Center Console Component Views Front of the I/P Components 1 - Inflatable Restraint Steering Wheel Module 2 - Inflatable Restraint I/P Module Front of the I/P Components (except YE9) Page 17033 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp - Right 6 - Object Alarm Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Alarm Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Alarm Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Alarm Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left Page 1038 Disclaimer Page 18295 4. Turn the sunshade cam (2) until it is aligned with the bracket (3) notch. 5. Install the sunshade. 6. Remove the suitable tool (1) from the sunshade cam locking hole (2). 7. Ensure that the sunshade cam (2) is fully seated in the bracket (3) and the sunshade slides smoothly. 8. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair)Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair) . 9. Verify the operation of the sunshade. Page 1484 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 19602 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 13758 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Page 9042 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10375 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 14623 Disclaimer Page 1542 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 7482 are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for the majority of vehicles. 44 vehicles will require replacement of the control solenoid valve (transmission controller) (see list below for listing of vehicles). Assemblies required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Refer to Programming and TEHCM Replacement Decision Table below. Page 9974 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 18725 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 19672 Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator Description and Operation (w/o AN3) Door Ajar Indicator Description and Operation (w/o AN3) Door Ajar Indicator System Components The door ajar indicator system consists of the following components: * The body control module (BCM) * The instrument panel cluster (IPC) * The driver door ajar switch * The passenger door ajar switch * The left rear door ajar switch * The right rear door ajar switch The body control module (BCM) receives a discrete inputs from the front and rear door ajar switches to indicate the status of the doors. The BCM then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Page 10839 For vehicles repaired under warranty, use the table. Note H9745 includes time for road testing and for removal of 1 rotor to inspect for OEM markings. Disclaimer Page 11128 8. Disconnect the brake master cylinder left supply brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. 9. Disconnect the brake master cylinder right supply brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination. Page 222 For vehicles repaired under warranty, use the table. Disclaimer Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13207 Page 2856 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Page 20845 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Page 6720 Page 3559 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Page 14536 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Page 9258 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Page 19342 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 11686 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 5821 1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and terminal 5 of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and ground. ‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. 3. If all circuits test normal, refer to the scan tool/CANdi module user guide. Repair Instructions Perform theDiagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the Powertrain High Speed GMLAN buss during normal vehicle operation. The Powertrain High Speed GMLAN is a differential bus. The Powertrain High Speed GMLAN serial data bus (+) and Powertrain High Speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the Powertrain High Speed GMLAN serial data bus (+) circuit and subtracts one volt from the Powertrain High Speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. Page 13972 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 9105 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 5584 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) (MX7) Rear of the Engine Compartment Components Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20387 Tail/Stop and Turn Signal Lamp - Upper Left Page 5104 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Page 12323 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 13464 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 9433 Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Drain the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement/Front Drive Axle) . 3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) . 5. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. 7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 9. Support the propeller shaft and move out of the way as necessary. Page 3737 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7916 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 585 Page 4887 Engine Control Module (ECM) X2 (4.8L/LY6 or 6.2L with Y91) Page 4319 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2871 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chassis Harness Routing (LY6/LMM except 31 Series) Page 15469 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10455 Actuator: Locations Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle Disassembled Views (9.25 Inch) Front Drive Axle (9.25 inch) Front Drive Axle (9.25 inch) 1 - Front Drive Axle Inner Shaft 2 - Front Drive Axle Inner Shaft Seal 3 - Front Drive Axle Inner Axle Shaft Bearing 4 - Front Drive Axle Inner Shaft Housing 5 - Front Drive Axle Clutch Gear Thrust Washer 6 - Front Drive Axle Clutch Gear 7 - Front Drive Axle Inner Shaft Retaining Ring 8 - Front Drive Axle Clutch Sleeve 9 - Front Drive Axle Clutch Shim 10 - Front Drive Axle Actuator 11 - Front Drive Axle Inner Shaft Housing Bolt 12 - Front Drive Axle Clutch Fork Assembly 13 - Front Drive Axle Clutch Fork Inner Spring 14 - Front Drive Axle Clutch Shaft Bearing 15 - Front Drive Axle Clutch Shaft 16 - Front Differential Carrier Bolt 17 - Front Differential Carrier 18 - Front Differential Carrier Half Location Pin 19 - Front Differential Case Bearing 20 - Front Differential Bearing Adjuster Nut 21 - Front Differential Bearing Adjuster Nut Sleeve 22 - Front Differential Side Bearing Cup 23 - Differential Ring Gear Bolt 24 - Front Differential Side Bearing 25 - Front Differential Pinion Gear Shaft Page 4152 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 4380 7. Remove the insulator (1) from the intermediate muffler assembly hanger and remove the muffler assembly. 8. If equipped with a 5.3L, or a 6.0L engine, perform the following steps. 9. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 10. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. Page 2127 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 9190 Use appropriate eye protection. 4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Important Position the valve body as shown in the following illustrations for positive identification and location of individual parts. Page 16612 Memory Seat Module (MSM) X7 (AN3) Page 14766 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 19684 Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Page 13865 X305 Body Harness to Passenger Seat Harness (Except AN3/MEX) X309 Page 20993 Page 1199 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 10920 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 17240 Auxiliary Body Control Module (XBCM) X2 (EXP) Page 10259 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 4886 Page 536 Page 13996 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 12693 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (4.8L, 5.3L, 6.0L and 6.2L) Page 12965 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1670 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 12238 Junction Block - Left I/P X11 (except MEX) Page 11857 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 412 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (Gas) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Pressure Sensor (Gas except 4.3L/LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly -Front (Gas) Left Side Frame and Underbody Components (HP2) Campaign - Inoperative OnStar(R) System Technical Service Bulletin # 08259A Date: 081106 Campaign - Inoperative OnStar(R) System CUSTOMER SATISFACTION Bulletin No.: 08259A Date: November 06, 2008 Subject: 08259A - OnStar(R) System Inoperative - Replace OnStar(R) Module Models Supercede: This bulletin is being revised to include the requirement of providing the current vehicle mileage and R.O. number, along with the VIN, when ordering OnStar(R) modules. Also, obtain all Bluetooth devices from the customer prior to programming the new VCIM. Please discard all copies of bulletin 08259, issued September 2008. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2009. Condition Certain 2009 model year Buick Enclave; 2008-2009 model year Cadillac CTS; 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX, STS, STS-V, XLR, XLR-V; Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse; GMC Acadia, Sierra, Yukon, Yukon XL; Pontiac G5, Solstice, Torrent; and Saturn OUTLOOK, SKY, and VUE vehicles may have an OnStar(R) module with a component that was not manufactured to GM's specification. This can result in an open circuit and an inability to call or receive calls from OnStar(R). Although a customer trying to make a call would hear the message, "Connecting to OnStar" and the LED light would blink green, no connection would occur. Correction Dealers/retailers are to replace the OnStar(R) module. Vehicles Involved Page 8374 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 18460 Memory Seat Module (MSM) X6 (AN3) Page 2833 Page 7407 13 - Transfer Case Two/Four Wheel Drive Shift Fork Assembly 14 - Transfer Case Two/Four Wheel Drive Actuator Cam 15 - Transfer Case Two/Four Wheel Drive Actuator Cam Retaining Ring 16 - Transfer Case High/Low Shift Fork 17 - Transfer Case High/Low Shift Fork Pads 18 - Transfer Case High/Low Shift Fork Spring Assembly 19 - Transfer Case High/Low Shift Fork Pin 20 Transfer Case Control Actuator Shaft 21 - Transfer Case Rear Output Shaft 22 - Transfer Case Two/Four Wheel Drive Synchronizer Inserts 23 - Transfer Case Two/Four Wheel Drive Synchronizer Hub 24 - Transfer Case Two/Four Wheel Drive Synchronizer Assembly 25 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring 26 - Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring 27 - Transfer Case Front Output Shaft Drive Chain Assembly 28 - Transfer Case Front Output Shaft Drive Sprocket 29 - Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly 30 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 31 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 32 Transfer Case Oil Pump Assembly 33 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 34 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 35 - Transfer Case Rear Output Shaft Rear Bearing Assembly 36 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 37 - Transfer Case Oil Pump Suction Pipe Seal 38 - Transfer Case Oil Pump Suction Pipe 39 - Transfer Case Front Output Shaft Rear Bearing Assembly 40 - Transfer Case Front Output Shaft Driven Sprocket Spacer 41 - Transfer Case Front Output Shaft Driven Sprocket 42 - Transfer Case Front Output Shaft Hole Plug 43 - Transfer Case Front Output Shaft 44 Transfer Case Front Output Shaft Front Bearing Assembly Page 1354 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (Except 10 Series) Page 12497 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Battery/Battery Cable/Service and Repair) . Page 13377 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel I/P Harness Routing - Engine Compartment (Except HP2) Page 16739 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 6745 30. Install the engine wiring harness bracket nut (1). Tighten the nut to 5 Nm (44 lb in). 31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 32. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for leaks. 33. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 9173 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 7750 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 11831 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 19960 Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement (GMC) Backup Lamp Bulb Replacement (GMC) Page 6550 4. Tighten the air cleaner outlet duct clamp (1) at the MAF/IAT sensor. Tighten the clamps to 4 Nm (35 lb in). 5. Install the radiator inlet hose clamp clip (2) to the air cleaner outlet duct (1). 6. Install the PCV line (1) to the air cleaner outlet duct. 7. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 13747 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Page 13773 X303 Body Harness to Driver Seat Harness (Except AN3/MEX) X303 Driver Seat Harness to Body Harness (MEX/A52) Page 18813 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 3639 13. Remove the spark plug wires (724) from the ignition coils. * Twist each plug wire 1/2 turn. * Pull only on the boot in order to remove the wire from the ignition coil. 14. Remove the ignition coil bracket studs (720). 15. Remove the ignition coil bracket (719). 16. Remove the positive crankcase ventilation (PCV) tube (1) from the valve rocker cover (2). Page 10183 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 4671 Accessory DC Power Control Module (APM) Location The APM is affixed to and located underneath the PIM. It is fastened to the PIM with external mounting fasteners and 2 internal high voltage circuit connection fasteners. The APM shares a coolant passage with the PIM and as such is gasketed to the PIM. Operating Functions The APM is the device which converts high voltage (300V) direct current (DC) to low voltage (12V) DC for accessory electrical operation and to charge the 12 volt accessory battery. The APM also converts HV DC to intermediate (42V) DC to supply the electric power steering system with voltage. The APM is capable of supplying up to 175 Amps of 12 volt DC and up to 50 Amps of 42 volt DC. In Jump Assist mode the APM converts 12 volt DC to HV DC to charge the high voltage hybrid batteries. The APM is capable of supplying up to 2.7 Amps at 290 volts DC on the high voltage circuit when operating in Jump Assist. An external 12V DC battery charger is required during the Jump Assist mode because the APM and vehicle controllers may draw as much as 80 Amps of current from the vehicles 12 volt DC system. Communication and Hosted Diagnostics The APM has internal diagnostic tests that run at both power-up and during operation. All DTCs from the APM are reported to and hosted by the HPCM. The APM communicates directly only with the HPCM and only on the high speed hybrid GMLAN communication circuit. Circuit Inputs Inputs supported by the APM include the high voltage and 12 volt circuits. The APM also monitors various internal components for current, voltage and temperature. The APM is also connected to the high speed hybrid GMLAN communication circuit. An individual 12 volt discrete circuit powers ON the APM. The APM will not begin conversion of voltage however, until the appropriate GMLAN enable signal is communicated to it by the HPCM. Circuit Outputs The only outputs supported by the APM are the 12 volt and 42 volt conversion during normal vehicle operation and high voltage conversion during Jump Assist. Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Component Locations Hazard Flasher Relay: Component Locations Passenger Compartment/Roof Component Views Overhead Console and Headliner Components (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infared Transmitter (U42) 4 - Blunt Cut Emergency Vehicle Provision (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Front Headliner Components - 1 of 2 Page 10589 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 6139 Camshaft Position (CMP) Sensor (Diesel) Page 5947 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 7343 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5489 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 11146 12. Remove the 4 brake pedal bracket nuts (1). 13. Remove the brake master cylinder adapter (1). 14. Inspect the master cylinder adapter gasket for damage and replace, if necessary. Installation Procedure Page 11715 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7083 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Specifications) 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the spark plug. Tighten the plug to 15 Nm (11 lb ft). Page 4804 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 14346 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 16323 Rear Vision Camera: Service and Repair Rearview Camera Replacement Page 8284 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 3914 30. Remove and discard the intake manifold gaskets (514). 31. If replacing the intake manifold, perform the following steps, otherwise proceed to step 21 of the installation procedure. 32. Place the intake manifold on a clean work surface. 33. Reposition the brake booster vacuum hose clamp at the intake manifold. 34. Remove the brake booster vacuum hose from the intake manifold nipple. Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Data Communications Diagnostic Starting Point - Data Communications Begin the system diagnosis withDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) . The Diagnostic System Check - Vehicle will provide the following information: * The identification of the control modules which are not communicating * The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis. Data Link References Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits refer toData Link Communications Description and Operation (See: Description and Operation) . Page 7475 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 6494 17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 20. Install the fuel line clip to the bracket on the automatic transmission. Page 10593 Transfer Case Shift Control Module X3 (NQF/NQH) Page 19385 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 19344 Cruise Control: By Symptom Technical Service Bulletin # 09-08-68-001 Date: 091114 Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12130 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ............................... Right Trailer Stop/Turn Lamp Fuse 2 ......................................................................................................................... Electronic Suspension Control, Automatic Level Control Exhaust Fuse 3 ............................................................................... .................................................................................................... Left Trailer Stop/Turn Lamp Fuse 4 .............................................................................................................................................................. ......................................... Engine Controls Fuse 5 ............................................................................. .................................................................................. Engine Control Module, Throttle Control Fuse 6 ........................................................................................................................................................... ............................... Trailer Brake Controller Fuse 7 ........................................................................... ................................................................................................................................ Front Washer Fuse 8 .................................................................................................................................................. ....................................................... Oxygen Sensor Fuse 9 ................................................................ ........................................................................................................................ Antilock Brakes System 2 Fuse 10 ................................................................................................................................ .......................................................... Trailer Back-up Lamps Fuse 11 ............................................... .......................................................................................................................... Driver Side Low-Beam Headlamp Fuse 12 ............................................................................................................ .............................................................. Engine Control Module (Battery) Fuse 13 ............................................................................................................................................................. Fuel Injectors, Ignition Coils (Right Side) Fuse 14 .............................................................................. .................................................................................. Transmission Control Module (Battery) Fuse 15 ......................................................................................................................................................... ................................ Vehicle Back-up Lamps Fuse 16 ........................................................................ ........................................................................................... Passenger Side Low-Beam Headlamp Fuse 17 ................................................................................................................................................ ................................ Air Conditioning Compressor Fuse 18 ................................................................ ..................................................................................................................................... Oxygen Sensors Fuse 19 ................................................................................................................................. .......................................... Transmission Controls (Ignition) Fuse 20 ................................................. ............................................................................................................................................................. Fuel Pump Fuse 21 ............................................................................................................................. .................................................... Fuel System Control Module Fuse 22 ............................................ .............................................................................................................................................................. ...... Not Used Fuse 23 ......................................................................................................................... ....................................................................................... Not Used Fuse 24 ........................................ ....................................................................................................................... Fuel Injectors, Ignition Coils (Left Side) Fuse 25 ..................................................................................................................... ........................................................................... Trailer Park Lamps Fuse 26 .................................... ..................................................................................................................................................... Driver Side Park Lamps Fuse 27 ......................................................................................................... .......................................................................... Passenger Side Park Lamps Fuse 28 ...................... .............................................................................................................................................................. ......................... Fog Lamps Fuse 29 ................................................................................................... .................................................................................................................... Horn Fuse 30 .................. ................................................................................................................................................. Passenger Side High-Beam Headlamp Fuse 31 ................................................................................. ........................................................................................... Daytime Running Lamps (DRL) Fuse 32 . .............................................................................................................................................................. ......... Driver Side High-Beam Headlamp Fuse 33 .............................................................................. ....................................................................................................... Daytime Running Lights 2 Fuse 34 ......................................................................................................................................................... ......................................................... Sunroof Fuse 35 ....................................................................................................................................................... Key Ignition System, Theft Deterrent System Fuse 36 ........................................................................ .......................................................................................................................... Windshield Wiper Fuse 37 ................................................................................................................................................ .......................... SEO B2 Upfitter Usage (Battery) Fuse 38 ................................................................ ..................................................................................................................... Electric Adjustable Pedals Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Engine - Valve Lifter Tick Noise At Start Up Engine Oil: Customer Interest Engine - Valve Lifter Tick Noise At Start Up TECHNICAL Bulletin No.: 10-06-01-007C Date: February 09, 2011 Subject: Active Fuel Management (AFM) Engine, Valve Lifter Tick Noise at Start Up When Engine Has Been Off for 2 Hours or More (Evaluate Noise and/or Replace Valve Lifters) Models: 2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2007 Cadillac Escalade Built Prior to April 1, 2006 with 6.2L Engine RPO L92 (These engines were built with AFM Hardware but the AFM system was disabled) 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Monte Carlo 2007-2009 Chevrolet Impala 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe, TrailBlazer, TrailBlazer EXT 2010-2011 Chevrolet Camaro SS 2007-2011 GMC Envoy, Envoy XL, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali 2007-2008 Pontiac Grand Prix 2008-2009 Pontiac G8 2007-2009 Saab 9-7X Equipped with AFM (Active Fuel Management) and V8 Engine RPO L76, L94, L99, LC9, LFA, LH6, LMG, LS4, LY5 or LZ1 Attention: This bulletin only applies to the AFM V8 engines listed above. It DOES NOT apply to Non-AFM Engines. If you are dealing with a Non-AFM engine that is experiencing a similar noise, please refer to Engine Mechanical > Diagnostic Information and Procedures > Symptoms in SI. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-06-01-007B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine valve lifter tick noise that occurs after the engine has been shut off for at least two hours. The tick noise may last from two seconds to ten minutes. Cause This condition may be caused by any of the following: - Aerated oil in the valve lifter body, resulting in the valve lifter being unable to purge the air quickly. - A low engine oil level or incorrect oil viscosity. - Dirty or contaminated oil. - A low internal valve lifter oil reservoir level. - Debris in the valve lifter. - A high valve lifter leak down rate. Correction If the SI diagnostics do not isolate the cause of this valve lifter tick noise and normal oil pressure is noted during the concern, perform the following steps: 1. Inspect the engine oil condition and level. Refer to Owner Manual > Service and Appearance Care > Checking Things Under the Hood > Description and Operation > Engine Oil in SI. ‹› If the engine oil is more than one quart low, an incorrect oil viscosity is being used or if poor quality/contamination is observed, change the oil and filter. Note Page 6988 Ignition Coil 4 (4.8L/5.3L/6.0L/6.2L) Page 4157 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 20895 2. Locate the underhood bussed electrical center (UBEC) (1). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse (1). 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 7 in this section of the bulletin 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 9. Secure the UBEC cover on the UBEC. 10. Close the hood. 11. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 12. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Cadillac CTS 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 20559 Heated Glass Element: Connector Views Component Connector End Views Rear Window Defogger Grid X1 (C49) Rear Window Defogger Grid X2 (C49) Page 6805 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 Nm (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 Gal Tank) Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 Gal Tank) Page 6871 Page 502 09-08-64-017A - END OF INFORMATION NEED Power Window Control Module: Technical Service Bulletins 09-08-64-017A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-64-017A Date: October 29, 2009 Subject: EI09133 - Power Windows Intermittently Inoperative (Engineering Information Closed) Models: 2009 Chevrolet Silverado 2009 GMC Sierra With RPO A31 Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-64-017 (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Fuel Pressure Relief (With CH-48027) Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH-48027) Fuel Pressure Relief (With CH-48027) Special Tools CH-48027 - Digital Pressure Gage Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Page 4452 Drive Motor Generator Battery Control Module X4 (HP2) Page 720 Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table above. Disclaimer Page 3219 Customer TPMS Information Page 13574 Junction Block - Rear Lamps X2 Locations Headlamp Switch: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 17820 Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Regular Cab) Page 13323 Page 17488 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (without SLT) Rear Side Door Inside Handle Replacement (without SLT) Page 16279 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 09-08-64-017A - END OF INFORMATION NEED Power Window Control Module: Technical Service Bulletins 09-08-64-017A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-08-64-017A Date: October 29, 2009 Subject: EI09133 - Power Windows Intermittently Inoperative (Engineering Information Closed) Models: 2009 Chevrolet Silverado 2009 GMC Sierra With RPO A31 Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-08-64-017 (Section 08 - Body and Accessories). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 17319 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure Note Perform theCrankshaft Position System Variation Learn (See: ) whenever the crankshaft position sensor is removed or replaced. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reposition the engine wiring harness sleeve (2). 3. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 4. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine. 5. Remove the CKP sensor bolt. 6. Remove the CKP sensor. Installation Procedure Page 645 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 2625 Fuse Block - Auxiliary X3 (HP2) Page 5419 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 13395 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 7264 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 2947 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA . Gently pry the TPA out of the connector. Page 9716 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Page 1285 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 16191 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 18649 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Specifications Compression Check: Specifications The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. Page 4706 Voltage Inverter Module: Diagrams Component Connector End Views Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Page 18842 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 1990 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3072 Page 9539 1. Place the propeller shaft assembly (3) on a block of wood. 2. Position the center bearing assembly (2) on the propeller shaft (3). 3. Using the J 22833 (1), install the center bearing assembly (2) on the propeller shaft (3). 4. For HD vehicles, use the J 24433 (1) to install the propeller shaft boot retainer (2) on the center bearing assembly (3). 5. Install the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) 6. Lower the vehicle. Page 15573 Clockspring Assembly / Spiral Cable: Diagrams Component Connector End Views Inflatable Restraint Steering Wheel Module Coil X1 Inflatable Restraint Steering Wheel Module Coil X2 Page 7973 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 11900 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 10429 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 14958 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Page 740 Component Locations Seat Occupant Sensor: Component Locations Passenger Compartment/Roof Component Views Under the Front Seats Components 1 - Yaw and Lateral Accelerometer Sensor (JL4/HP2) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Under the Rear Seat Components (HP2) Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Diagrams Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Page 5259 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement) . 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair) . Locations Vehicle Speed Sensor: Locations Powertrain Component Views Transfer Case Components (NQG) 1 - Transfer Case Shift Control Switch 2 - Vehicle Speed Sensor (VSS) Transfer Case Components (NQH/NQF) Page 1417 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 12089 Fuse Block - I/P Top View Page 13371 Mega Fuse Electrical Center Identification Views Mega Fuse X1 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Battery Positive Harness) (Gas except 9L4) Mega Fuse X2 (Engine Harness) (4.3L except 9L4) Mega Fuse X2 (Generator Harness) (Gas except 4.3L/9L4) Page 18860 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Door Striker Replacement (Crew Cab) Front Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Door Striker Replacement (Crew Cab) Removal Procedure Note If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Page 19044 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 4076 1. Correctly position the spark plug washer. 2. Inspect the spark plug gap. Adjust the gap as needed. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) 3. Hand start the spark plug in the corresponding cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the spark plug. Tighten the plug to 15 Nm (11 lb ft). Page 8293 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 2552 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 3869 Refer to Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing (See: Testing and Inspection/Component Tests and General Diagnostics) . Locations Camshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 5174 Page 18404 For vehicles repaired under warranty, use the table above. Disclaimer Page 2236 Alignment: Description and Operation Toe Description Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 8079 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 17545 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Page 12431 Junction Block - Left I/P, Top View Junction Block - Left I/P, Bottom View Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15121 HVAC Control Module X3 (C67/C42/CJ2/MEX) Page 1576 Page 1513 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Under the Front Seats Components Page 19839 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 14527 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 5190 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 12655 Page 4560 Drive Motor Temperature Sensor: Diagrams Component Connector End Views Generator Control Module Temperature Sensor (HP2) Generator Battery Vent Fan (HP2) Page 13296 Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 19591 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5848 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Page 20537 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer Removal Procedure Note The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Note In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) . 4. Remove the axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) . 5. Remove the axle nut retaining ring. 6. Remove the key. Page 4436 Drive Motor Generator Battery Control Module X2 (HP2) Page 4074 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. If replacing the right side spark plug(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug(s) through the wheel opening. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 2. If replacing the right side spark plug(s), perform the service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 3. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. Page 5768 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 16392 2. The BLUETOOTH button will appear on the Nav Radio screen. Disclaimer Page 15246 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 8118 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 12971 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Page 5766 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 8462 Director, Customer and Relationship Services 09241 Page 18721 For vehicles repaired under warranty, use the table. Disclaimer Page 8724 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Fuel Level Sensor Replacement Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 12306 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 4344 2. If equipped with a Allison(R) automatic transmission, RPO MW7, install the exhaust pipe hanger bracket and bolt/stud and tighten to 25 Nm (18 lb ft) . 3. If equipped with a 4L80-E automatic transmission, RPO MT1, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft) . 4. If equipped with a 6.6L engine, install the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With V8 Engine) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (With LMM) (See: Catalytic Converter/Service and Repair) . 5. If equipped with a 6.0L engine, install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (With Cab Chassis) (See: Catalytic Converter/Service and Repair) . 6. If equipped with a 6.0L engine, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement) . Page 12876 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 11173 Disclaimer Page 8095 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6286 4. Install the CPA retainer (3). 5. Install the HO2S clip to the engine wiring harness clip (4). 6. Lower the vehicle. Page 17173 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 19722 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 16414 - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information U.S.: OnStar(R) modules required for this recall are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 08259 (or PIC 4916). Dealer must provide the VIN, R.O. number and the current vehicle mileage. Canada: OnStar(R) modules required for this recall are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number and the current vehicle mileage. DO NOT ORDER ONSTAR MODULES FROM GENERAL MOTORS SERVICE AND PARTS OPERATIONS (GMSPO), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Service Procedure 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note: Bluetooth devices must be paired with the new VCIM. Obtain all Bluetooth devices from the customer before programming the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install a new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject. Claim Information - GM, Saturn Canada Only Page 15004 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 10611 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Ball Joint Inspection (Lower Ball Joint) Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . 4. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Lower Control Arm Ball Joint Replacement (See: Service and Repair) . 5. Install and position the dial indicator fromJ 8001 against the end of the ball joint. Important: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 6. Gently lift or pry the suspension upward then let it settle. 7. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification, replace the ball joint. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 8299 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 8998 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 18293 6. Lift upward on the sunshade (1) removing it from the bracket (2). Important: The sunshade must be removed from the top of the vehicle. 7. Push the sunshade (1) inward to the driver side releasing it from the bracket (2) notch. 8. Remove the sunshade from outside of the vehicle. Installation Procedure 1. Install the sunshade to the vehicle from the passengers side. A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 13263 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 12021 Fuse: Locations Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Page 7829 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 19873 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 11638 Page 12665 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Page 14443 Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Page 20449 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 5200 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 8368 Director, Customer and Relationship Services 09241 Page 7743 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6893 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 8860 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7556 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18879 Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation/Heated Seats Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, observe the appropriate scan tool Driver Door Switch or Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active. * Seat Back Heat Mode Sw. * Seat Heat Mode Sw. ‹› If not the specified values, refer to the Heated Seat Switch component test. If the heated seat switch tests normal, replace the appropriate door lock/window switch. 2. If all scan tool parameters test normal and there are no DTCs set, replace the MSM. 3. If all heated seat functions operate normal and the heated seat switch indicators do not illuminate, refer to the Heated Seat Switch Indicators component test. Component Testing Heated Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the open position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If not the specified value, replace the heated seat switch. 3. Test for less than 2 Ω between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the closed position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If greater than the specified range for any of the tests, replace the heated seat switch. Heated Seat Switch Indicators 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 3. Connect a test lamp between B+ and each control circuit listed below. The appropriate indicator should illuminate. * Seat back and cushion mode indicator terminal 10 * Seat back only mode indicator terminal 11 * Low heat indicator terminal 9 * Medium heat indicator terminal 1 * High heat indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated seat switch. 4. If all indicators illuminate, replace the door lock/window switch. Repair Instructions Page 2329 1. Route the drive belt (1) around all the pulleys except the idler pulley. 2. Install the breaker bar with hex-head socket to the belt tensioner bolt. 3. Rotate the belt tensioner (2) clockwise in order to relieve the tension on the tensioner. 4. Install the drive belt under the idler pulley. 5. Slowly release the tension on the belt tensioner. 6. Remove the breaker bar and socket from the belt tensioner bolt. 7. Inspect the drive belt for proper installation and alignment. 8. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Filters/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . Page 9069 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 20882 Notice to Customer General Motors released this product recall in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act because a defect that relates to motor vehicle safety exists in your vehicle. It was implemented to address the potential consequences of a printed circuit board electrical short within the Heated Washer Fluid System (HWFS). The significance of this failure can vary from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. This failure can occur at any time, even when the vehicle is unattended - parked and key not in the "ON" position. Note that a resulting under hood fire could also involve other nearby vehicles or structures. Performance of this recall procedure will allow your GM dealer to eliminate these risks by permanently removing the HWFS from your vehicle. In addition to the risk of a thermal incident, including a fire, it is possible that the HWFS will become inoperative at a future time. If this occurs, it will not be repaired or replaced by GM. Note that GM does not endorse or otherwise approve the Page 14002 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Diagrams Barometric Pressure Sensor: Diagrams Component Connector End Views Barometric Pressure (BARO) Sensor (HP2) Page 9437 Seals and Gaskets: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement) . 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) . Note The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) . Note Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer toOne-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) . * For vehicles equipped with a two piece propeller shaft, refer toTwo-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) . Note Page 11234 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 12598 X109 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (NQF/NQH/HP2 Except Late Production with 4.8L/5.3L/6.0L/6.2L) Page 2803 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 11130 12. Remove the brake master cylinder nuts (1). Discard the brake master cylinder nuts. 13. Remove the brake master cylinder and the master cylinder seal (1). Installation Procedure 1. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (Non-Hybrid) (See: Procedures/Hydraulic Brake System Bleeding (Manual with RPO BRM))Master Cylinder Bench Bleeding (Two-mode Hybrid) (See: Procedures/Hydraulic Brake System Bleeding (Manual without RPO BRM)) . Page 18821 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 1291 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Locations Exhaust Temperature Sensor: Locations Wheels/Vehicle Underbody Component Views Right Side Frame and Underbody Components (Diesel) 1 - Rear Frame Assembly 2 - Exhaust Temperature Sensor 2 3 - Exhaust Temperature Sensor 1 4 - Exhaust Differential Sensor Page 7233 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 7261 TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: All Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 6822 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 18964 Door Lock/Window Switch - Driver X7 (AN3/DL3) Page 5685 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 15435 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Page 19977 Center High Mounted Stop Lamp (CHMSL) X4 Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: All Technical Service Bulletins Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20458 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 6492 19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 22. Remove the fuel line bracket bolt (1). 23. Remove the fuel/EVAP line clip nut (2). 24. Remove the fuel/EVAP line clips from the frame and crossmember. 25. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure 1. If equipped with 4WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Interior - Seat Memory Inopertive After Air Bag Deploys Memory Positioning Module: Customer Interest Interior - Seat Memory Inopertive After Air Bag Deploys TECHNICAL Bulletin No.: 09-08-50-014 Date: August 28, 2009 Subject: Memory Function of Memory Seats Inoperative After Air Bag Deployment (Reprogram Memory Seat Module) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2009 GMC Sierra, Yukon, Yukon XL 2008-2009 HUMMER H2, H2 SUT Built Between April, 2008 and May, 2009 Condition Some customers may comment that the memory function of the memory seats becomes inoperative after an air bag deployment. Vehicles built between of April 2008 and May, 2009 that have incurred an air bag deployment will no longer have seat memory functionality. The memory set and recall features will exhibit no automatic recalls, and no set or recall through the memory switches, along with no audible feedback. The driver seat/column/pedal can still be moved with the appropriate switches. The heat/cool functionality is not affected. Cause This condition may be caused by the air bag deployed flag getting permanently stored in the memory seat module. Correction Reprogram the Memory Seat Module (MSM) with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the MSM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Memory Seat Control Module Programming and Setup in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15596 Page 268 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 11692 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3384 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 20853 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 11403 Page 8182 2-3 Shift Solenoid (SS) Valve (M30) Shift Solenoid (SS) Valve 1 (MW7) Page 884 Steering Control Module: Service and Repair Electronic Power Steering Motor Control Module Replacement Page 10345 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6250 1. Install the MAP sensor. 2. Install the MAP sensor retainer. 3. Connect the engine harness wiring electrical connector (4) to the MAP sensor (1). 4. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Page 12115 Junction Block - Left I/P X11 (except MEX) Service and Repair Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Page 16167 1 - Sunroof 2 - Sunshade -Right 3 - Windshield Outside Moisture Sensor (CE1) 4 - Inside Rearview Mirror (ISRVM) Window Anchor Front Headliner Components - 2 of 2 Page 493 Front of the I/P -YE9 1 - Driver Information (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 - Ambient Light/Sunload Sensor (CJ2)/Ambient Light Sensor (C67/C42/MEX) 5 - HVAC Control Module 6 Inflatable Restraint I/P Module Disable Switch (C99/MEX) 7 - Power Take-Off (PTO) Switch (PTO) 8 - Accessory Power Outlet - I/P 2 9 - Multifunction Switch Assembly - I/P (except MEX) 10 Accessory Power Outlet - I/P 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Front of the I/P Components (YE9) Page 2257 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis (W/O FPCM) Fuel System Diagnosis (w/o FPCM) Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Special Tools * CH-48027 Fuel Pressure Gage * J 37287 Fuel Line Shut-Off Adapters Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. 1. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer toFuel System Diagnosis (w/o FPCM) Fuel System Diagnosis (w/FPCM) (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics) . 2. Ignition OFF, all accessories OFF, install theCH-48027 . Refer to Fuel Pressure Gage Installation and Removal (See: Fuel Pressure Gage Installation and Removal) . 3. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: Page 20442 * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the difference in voltage potential between 2 points. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . Note When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Page 18058 Door Lock/Window Switch - Driver X3 (AN3/DL3) Page 12572 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 9802 Page 5693 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 5958 Auxiliary Body Control Module (XBCM) X2 (EXP) Page 13271 Fuse Block - Underhood Bottom View Page 19560 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 8307 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Page 19770 Customer TPMS Information Page 3972 5. Compress the timing chain tensioner guide and install the EN 46330 . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 6. Install the timing chain tensioner (232) and bolts (231). Tighten the bolts to 25 Nm (18 lb ft). Page 4874 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (4.3L) Page 18792 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum - Hot at 1,000 RPM........................................................................................ .......................................................................................................250 kPa (36 psig) at 2,000 RPM... .............................................................................................................................................................. ..............................290 kPa (42 psig) at 4,000 RPM............................................................................ ...................................................................................................................310 kPa (45 psig) Page 5156 4. Install the CPA retainer (3). 5. Install the HO2S clip to the engine wiring harness clip (4). 6. Lower the vehicle. Page 3618 Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 13274 Fuse Block - Underhood X2 Page 6056 Engine Control Module (ECM) X3 (HP2) Page 6418 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 15397 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Page 19297 Disclaimer Page 2885 1 - Windshield Wiper Motor 2 - Windshield Washer Solvent Heater (XA7) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Transmission Control Module (TCM) (M30/MW7) 6 - Brake Booster Vacuum Sensor (JL4 with 10 Series)/Brake Master Cylinder Pressure Sensor (JL1) 7 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (HP2) Page 13830 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Page 7659 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 7074 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (3) to knock sensor. 3. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 11862 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 18852 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 4666 Drive Motor Generator Battery Control Module X4 (HP2) Page 2757 Page 2513 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft) . 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities andFluid and Lubricant Recommendations in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft) . 4. Lower the vehicle. Page 10018 Note Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 6. Lower the vehicle. Page 861 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 18854 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 5878 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 2764 Fuse Block - Underhood X2 Page 2723 Junction Block - Left I/P X13 (AN3) Page 10812 Page 10285 6. View of the female half of the connector with male terminals. 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers Page 10363 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6699 Right Side of the Engine Components (Diesel) 1 - Fuel Injector 7 2 - Fuel Injector 5 3 - Fuel Injector 3 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Fuel Injector 1 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 7 - Intake Air Valve 8 - Crankshaft Position (CKP) Sensor 9 - Glow Plug 1 10 - G103 11 - G105 12 - Block Heater 13 - Glow Plug 3 14 - Glow Plug 5 15 - Water In Fuel Sensor 16 - Starter Motor 17 - Glow Plug 7 Rear of the Engine Components (Diesel) Page 15997 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Page 4597 Drive Motor Generator Battery Control Module X4 (HP2) Locations Power Door Lock Switch: Locations Door Component Views Passenger Door Components (except AN3/DL3) 1 - Door Lock Switch -Passenger (AU3) 2 - Door Latch -Passenger 3 - Speaker -Right Front Passenger Door Components (AN3/DL3) Page 14995 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Install the blower motor insulating cover screws and tighten to 1.6 Nm (14 lb in) . 6. If equipped, install the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 15371 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Page 14398 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 11698 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7789 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9287 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Page 2678 Page 11930 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 19478 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Specifications Crankshaft: Specifications Crankshaft Connecting Rod Journal Diameter Production..........................................................................................................53.318-53.338 mm (2.0991-2.0999 in) Connecting Rod Journal Diameter - Service.......................................................... ..............................................................................53.308 mm (2.0987 in) Connecting Rod Journal Out-of-Round Production.............................................................................................................................0.005 mm (0.0002 in) Connecting Rod Journal Out-of-Round Service.....................................................................................................................................0.01 mm (0.0004 in) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length Production..............................................................................0.005 mm (0.0002 in) Connecting Rod Journal Taper - Maximum for 1/2 of Journal Length Service...................................................................................0.02 mm (0.00078 in) Crankshaft End Play....................................................................................................................................................... .......0.04-0.2 mm (0.0015-0.0078 in) Crankshaft Main Bearing Clearance Production.............................................................................................................0.02-0.052 mm (0.0008-0.0021 in) Crankshaft Main Bearing Clearance Service...................................................................................................................0.02-0.065 mm (0.0008-0.0025 in) Crankshaft Main Journal Diameter Production.............................................................................................................64.992-65.008 mm (2.558-2.559 in) Crankshaft Main Journal Diameter - Service............................................................. .............................................................................64.992 mm (2.558 in) Crankshaft Main Journal Out-of-Round Production........................................................................................................................0.003 mm (0.000118 in) Crankshaft Main Journal Out-of-Round Service..................................................................................................................................0.008 mm (0.0003 in) Crankshaft Main Journal Taper - Production...................................................................... .....................................................................0.01 mm (0.0004 in) Crankshaft Main Journal Taper - S ervice...............................................................................................................................................0.0 2 mm (0.00078 in) Crankshaft Rear Flange Runout............................................................................. .....................................................................................0.05 mm (0.002 in) Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in) Below Tooth Diameter.............................................................................0.7 mm (0.028 in) Crankshaft Thrust Surface - Production............................................................................................................................. 26.14-26.22 mm (1.029-1.0315 in) Crankshaft Thrust Surface - Service............................................. ..........................................................................................................26.22 mm (1.0315 in) Crankshaft Thrust Surface Runout....................................................................................................... ....................................................0.025 mm (0.001 in) Page 4574 Voltage Inverter Module: Locations Passenger Compartment/Roof Component Views Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label Page 16456 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Transmitter Replacement Page 6715 kPa (43 - 45 psi). Circuit/System Testing Important: * The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH-48027)) . 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 . 4. Ignition ON, command the fuel pump ON with a scan tool and bleed the air from theCH-48027 . 5. Command the fuel pump ON and then OFF with a scan tool. 6. Close the valve on the J 37287 . 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s). ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with theCH-48027 . The fuel pressure should not drop off during acceleration, cruise or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections 5. If the fuel system tests normal, refer toSymptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls) . Repair Instructions Perform theDiagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Hose/Pipes Replacement - Chassis (2500/3500 Regular Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Crew Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended/Crew Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement Chassis (1500 Regular Cab) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (1500 Extended Cab - w/8 Ft Bed) (See: Fuel Supply Line/Service and Repair)Fuel Hose/Pipes Replacement - Chassis (2500/3500 Extended Cab) (See: Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair/Removal and Replacement) * Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Service and Repair )Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Service and Repair) Page 19771 Page 20580 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Right Rear Door Components (Extended Cab) Page 15278 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 18678 Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Page 6723 Page 859 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab with 10 Series with ASF) Page 4949 Drive Motor Battery Components Drive Motor Control Module: Locations Drive Motor Battery Components Passenger Compartment/Roof Component Views Drive Motor Battery Components 1 - Battery Case Upper Cover Assembly 2 - Battery Upper Cover Nut 3 - Bar Code Label 4 Battery Danger Label 5 - Drive Motor Battery Case Upper Cover Bolt 6 - Battery Side Cover Nut 7 Drive Motor Battery Right Side Cover 8 - Drive Motor Battery Side Cover Bolt 9 - Battery Caution Label Page 17097 1 - Wheel Speed Sensor (WSS) -Left Rear 2 - Wheel Speed Sensor (WSS) -Right Rear Page 15279 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 18011 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 12263 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Page 1906 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure Note Clean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Disconnect the engine wiring harness electrical connector (3) from the CMP sensor wire harness. 4. Disconnect the CMP sensor wire harness electrical connector (1) from the CMP actuator magnet. Service and Repair Parking Assist Warning Indicator: Service and Repair Information Center Telltale Assembly Replacement Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 18731 Harness Components Page 13250 Junction Block - Rear Lamps X3 Page 7736 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 19699 Fuel Pump and Sender Assembly - Rear (LY6 without NQZ Except MEX) Page 1978 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 11106 11. Remove the brake pipe manifold (1). 12. Remove the supply and return transfer tubes (1). Remove and discard the O-ring seals. Page 9895 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) OnStar(R) - Destination Download Incomplete/Intermittent Emergency Contact Module: Customer Interest OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 2177 Door Lock/Window Switch - Driver X3 (AN3/DL3) OnStar(R) - Generation 8 Modules Inop./Battery Discharge Technical Service Bulletin # 09-08-46-004A Date: 091217 OnStar(R) - Generation 8 Modules Inop./Battery Discharge TECHNICAL Bulletin No.: 09-08-46-004A Date: December 17, 2009 Subject: Generation 8 OnStar(R) Modules Inoperative and Possible Battery Discharge Condition (Replace OnStar(R) VCIM) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS 2009 Cadillac Escalade, Escalade ESV, Escalade EXT, STS, XLR 2009 Cadillac SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, HHR, Silverado, Suburban, Tahoe, Traverse 2009 Chevrolet Equinox 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Pontiac G5, G8, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE All Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the models involved and add further clarification to the special program and vehicle conditions/involvement. Additionally, a revised sample customer notification letter is shown. Please discard Corporate Bulletin Number 09-08-46-004 (Section 08 Body and Accessories). Condition Important This bulletin is being issued to provide the dealers with information regarding a condition pertaining to vehicles equipped with a Generation 8 OnStar(R) Vehicle Communication Interface Module (VCIM). Some customers may comment that they are not able to contact the OnStar(R) Center and that the vehicle is unable to make or receive OnStar(R) hands-free calls. This condition also affects vehicles enrolled in OnStar(R) vehicle diagnostics such that the monthly e-mail may not be sent to the subscriber as scheduled. OnStar(R) may also be unable to perform any outbound services, such as door unlocks. In some instances, under certain circumstances, a battery discharge condition may also be experienced. Affected Unit StID Ranges Note Not all units within the StID ranges are involved. 29,800,000 - 31,125,426 38,000,000 - 39,175,239 Customer Notification OnStar(R) will notify subscribers on a case-by-case basis. OnStar(R) customer notification letters (shown in this bulletin) will include a reference to this bulletin. The customer letter request they test the OnStar(R) system by pressing the Blue and/or Red buttons. If the system is successful in connecting to the OnStar(R) Call Center NO further action is required, and the unit does NOT require replacement. If the unit is unable to successfully contact the OnStar(R) Call Center, the customer is advised to contact their dealer for replacement. Vehicle Identification Numbers (VINs) of customers receiving letters will be included in the special part ordering process noted below. Dealers attempting to order units for vehicles not included in the special ordering process will be referred to Technical Assistance for aid in diagnosis of the vehicle concern. Some customers may also be referred to the dealer by OnStar(R) Technical Assistance following attempts to resolve any of the listed concerns. Subscribers will be directed to contact their GM dealer to schedule an appointment to have the OnStar(R) VCIM replaced. Correction Page 15156 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8144 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 16697 Speaker: Locations Passenger Compartment/Roof Component Views Left A-Pillar Components (UQ3/UQA) 1 - Left A-Pillar Trim Panel 2 - Speaker -Left Front Tweeter (except MEX) 3 - Speaker -Left Front Tweeter Connector (except MEX) Right A-Pillar Components (UQ3/UQA) Page 7280 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16398 Disclaimer Page 554 Hazard Flasher Relay: Connector Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 1674 Camshaft Position (CMP) Sensor (Diesel) Page 3885 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 803 Page 5353 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 7440 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 16252 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2) Page 5065 Page 7050 1. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the CKP sensor bolt. Tighten the bolt to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 4. Position the engine wiring harness sleeve (2) over the CKP sensor electrical connection. 5. Lower the vehicle. 6. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: ) . Service and Repair Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement Page 3911 7. Remove the connector position assurance (CPA) retainer (1). 8. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 9. Disconnect the engine harness electrical connectors (3) from the left side fuel injectors. 10. Remove the engine harness clip (4) from the ignition coil bracket stud. 11. Remove the CPA retainer (2). 12. Disconnect the engine harness electrical connector (1) from the ignition coil harness electrical connector. 13. Disconnect the engine harness electrical connector (3) from the throttle actuator. 14. Remove the engine harness clip (4) from the generator battery jumper cable. 15. Remove the engine harness clip (6) from the ignition coil bracket stud. 16. Disconnect the engine harness electrical connectors (7) from the right side fuel injectors. 17. Remove the engine harness clip (1) bolt (3). 18. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor. 19. Gather the engine harness branches and tie the harness up out of the way to the cowl panel. Page 7199 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10106 Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Page 10721 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings) . Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Place the ignition switch in the OFF position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 3. Remove the antilock brake system (ABS) module splash shield retainer (1). Page 355 For vehicles repaired under warranty, use the table. Disclaimer Page 13393 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Left Rear of the Engine Compartment Components Page 8827 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 7887 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13459 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20556 * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) US English/Metric Conversion US English/Metric Conversion Locations Amplifier: Locations Instrument Panel/Center Console Component Views Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 15434 Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 14521 Note For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 3. Position the shock absorber (2) in the upper retaining bracket of theCH-48845 (1) so the shock absorber will be centered. Diagrams Safety Disconnect Impact Sensor: Diagrams Component Connector End Views High Voltage Circuit Impact Detection Sensor (HP2) Page 11915 Note During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: Customer Interest Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Page 382 Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 12355 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 11054 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). Page 13848 X215 Inline Harness Connector End Views X215 Body Harness to I/P Harness (HP2) Page 11588 18. Remove the auxiliary battery positive cable from the vehicle. Installation Procedure 1. Install the auxiliary battery positive cable to the vehicle. Page 17468 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 1349 Right Rear Frame Rail (31 Series) 1 - Trailer Brake Control Relay 2 - Trailer Brake Control Module Rear Frame and Underbody Components (JL4) Page 8880 Control Solenoid Valve Assembly X3 (MYC/MYD) 1-2 Shift Solenoid (SS) Valve (M30) Page 592 Page 8261 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Page 15248 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 15102 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 9066 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 12382 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Campaign - Transmission Clutch Housing Fracture Technical Service Bulletin # 09241B Date: 101025 Campaign - Transmission Clutch Housing Fracture CUSTOMER SATISFACTION Bulletin No.: 09241B Date: October 25, 2010 Subject: 09241B - Transmission Clutch Housing Fracture - Reprogram Transmission Controller Models: 2009 Cadillac Escalade 2008-2009 Chevrolet Tahoe 2009 Chevrolet Silverado 2008-2009 GMC Yukon 2009 GMC Sierra Equipped with a Two-Mode Hybrid Transmission (RPO M99) Supercede: The expiration date for this program has been extended to October 31, 2011. Please discard all copies of bulletin 09241A, issued October 2009. THIS PROGRAM IS IN EFFECT UNTIL OCTOBER 31, 2011. Condition Certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Correction Dealers are to reprogram the transmission controller to reduce the clutch pressure. Some vehicles will also require the replacement of the control solenoid valve. Vehicles Involved Involved are certain 2008-09 Chevrolet Tahoe and GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, and GMC Sierra vehicles, equipped with a Two-Mode Hybrid Transmission (RPO M99), and built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you Page 15827 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 2793 Fuse Block - I/P X4 Page 9688 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 11705 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 13624 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( See: Starting and Charging/Battery/Battery Cable/Service and Repair) . 175 Amp Mega Fuse Replacement (With Single Battery) 175 Amp Mega Fuse Replacement (With Single Battery) Removal Procedure Page 2903 Page 19039 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 1019 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Transmission Control Module (TCM) (M30) Component Locations Power Seat Switch: Component Locations Passenger Seat Components - 1 of 2 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 8907 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to OnStar(R) - Destination Download Incomplete/Intermittent Global Positioning System: Customer Interest OnStar(R) - Destination Download Incomplete/Intermittent TECHNICAL Bulletin No.: 08-08-46-003C Date: August 07, 2009 Subject: Information on OnStar(R) Destination Download Incomplete, Intermittent (Replace OnStar(R) (VCIM) Module) Models: 2009 Buick Enclave 2008-2009 Cadillac CTS, CTS-V 2009 Cadillac Escalade, Escalade ESV 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK, VUE All Equipped With Gen 8.0 OnStar(R) (RPO UE1) and Navigation Radio (RPOs U3R, UVB, U3U, UAV or UZR) Supercede: This bulletin is being revised to change the Warranty Information. Please discard Corporate Bulletin Number 08-08-46-003B (Section 08 - Body & Accessories). Condition Note For the model year vehicles mentioned above, the "Directions and Connections" service package will allow the driver to request directions from OnStar(R). Vehicles equipped with OnStar(R) and a navigation radio may experience intermittent failure to download directions to the navigation radio. Customers will call OnStar(R) for directions, OnStar(R) will download the destination to the vehicle and the customer will hear "Your destination is being sent to your vehicle. When safe and appropriate, press the Go button and follow instructions on your navigation screen to begin your route." However, the customer may not see the Go button, or the Go button on the navigation screen may be unresponsive, and therefore unable to be pressed in order to start the directions. Cause This condition may be caused by any of the following: - The navigation disc is not inserted in the radio. Some radios may display a message that states that the map disc must be inserted for destination download. - An OnStar(R) (VCIM) module software anomaly. The OnStar(R) destination download does not complete communicating to the navigation radio within a certain time frame. - A navigation radio software anomaly. This applies to 2008-2009 CTS and CTS-V vehicles with RPO UAV. Correction Important DO NOT replace the navigation radio for any of these conditions. - If the navigation disc is not installed, insert the navigation disc and test the operation of the system. - For 2008-2009 CTS and CTS-V vehicles with RPO UAV, update the navigation radio software. Refer to Corporate Bulletin Number 08-08-44-019A. - For all other vehicles, an updated OnStar(R) VCIM is now available. Replace the OnStar(R) VCIM. Refer to OnStar(R) Module VCIM Replacement in SI. Parts Information DO NOT OBTAIN PARTS FROM GMSPO. Contact an authorized Electronic Service Center for replacement. The following list provides the updated part number information: Page 7181 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 11512 Page 19434 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2363 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 2707 Junction Block - Left I/P, Top View Page 13826 X175 Engine Harness to Transmission Internal Harness (M30) Page 20 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 19439 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 3638 11. Remove the surge tank outlet hose (2) from the heater hose bracket (3). 12. Remove the heater hose bracket nut (1) and bracket (2). Page 5371 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Page 18919 Seat Climate Control Module X1 (KB6) Page 10019 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Page 3904 14. Install the upper intake manifold cover. 15. Install the upper intake manifold cover nut until snug. 16. Install NEW intake manifold gaskets (514) to the intake manifold. 17. Remove the covers from the cylinder head passages. Page 17043 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () orRear Bumper Impact Bar End Cap Replacement () . Locations Transmission Position Switch/Sensor: Locations Hybrid Controls Electronic Component Views Hybrid Control Electronic Component Views 1 - Drive Motor Generator Control Module Assembly 2 - Accessory DC Power Control Module (APM) Assembly 3 - Drive Motor Generator Power Inverter Module (PIM) Assembly 4 - Hybrid Powertrain Control Module (HPCM) 5 - Motor Control Module (MCM) 1, Motor Control Module (MCM) 2 6 - Sight Shield Circuit Breaker 7 - Drive Motor Generator Power Inverter Module 3 Phase Cable Assembly 8 - Drive Motor Battery 300 Volt Positive and Negative Cable Assembly 9 - Drive Motor Generator Assembly - 1st Position 10 - Drive Motor Generator Assembly - 2nd Position 11 A/Trans Output Speed Sensor Assembly 12 - Drive Motor Generator Battery 13 - Drive Motor Generator Battery Control Module Assembly 14 - Drive Motor Battery Cable Terminal Extension Cover Circuit Breaker 15 - Drive Motor Generator Power Inverter Module 3 Phase Cable Cover Circuit Breaker 16 - A/Trans Manual Shift Shaft Position Switch Assembly 17 - Control Solenoid w/Body and TCM Valve Assembly 18 - A/Trans Auxiliary Fluid Pump Control Module Assembly 19 A/Trans Auxiliary Fluid Pump Assembly 20 - 300 Volt AC Compressor w/Control Module Assembly Page 17887 Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Extended Cab) Page 18865 Heated Seat Element - Passenger Back (AN3 without KB6) Page 10269 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 17721 Page 14929 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 16606 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat Harness Routing 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Page 19397 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2839 Junction Block - Left I/P X5 (SPO Alarm) Page 19608 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 2722 Junction Block - Left I/P X12 (except MEX) Page 6792 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 Gal Tank) Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 11916 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13886 X800 Right Rear Door Harness to Body Harness (Extended Cab) Page 2730 Junction Block - Right I/P X3 Page 7727 Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure determines the frequency of a signal. Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. Page 20175 Page 5678 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 11338 Page 14143 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5799 High Speed Bus - 4 of 6 (MEX) Page 16127 9. Remove the scan tool. 10. Exit the vehicle. Operate all functions on transmitters to verify correct system operation. Page 5470 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 725 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 1911 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the 2 rear CMP sensor wire harness bolts (1). Tighten the bolt to 12 Nm (106 lb in). 9. Working through the crankshaft balancer opening, tighten the CMP sensor wire harness bolt (1) using a box wrench. Page 9554 Replace Transfer Case Rear Output Shaft Note Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective. 1. Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI. 2. Disassemble the transfer case. Refer to Transfer Case Disassemble in SI. 3. Replace the transfer case rear output shaft. Refer to the Parts Information below. 4. Assemble the transfer case. 5. Reinstall the transfer case assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13428 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8850 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 2569 2. Turn the ignition key to the "OFF" position, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 4. Without the brake pedal applied, turn the ignition key to the "ON" position, with the engine OFF. 5. Using the Tech 2(R) scan tool, check the brake pedal travel using the steps below: 1. Select Diagnostics. 2. Build the appropriate vehicle information. 3. Select Chassis. 4. Select if the vehicle is equipped with Magnetic Ride Control Suspension Package (RPO Z95). 5. Select Electronic Brake Control Module (EBCM). 6. Select Data Display. 7. Under the Data List, scroll down the list and select "BMC Primary Piston Ref. Position" and "Master Cylinder Pressure Sensor" items as shown: Note First highlight the line and press the "Enter" soft key on the Tech 2(R) to get the "*" as shown for each item. - BMC Primary Piston Ref. Position - Master Cylinder Pressure Sensor - Then "Accept" the two selected items as shown on the top of the Tech 2(R) scan tool. 6. While observing the Master Cylinder Pressure Sensor on the scan tool data display, using moderate speed and moderate effort, depress the brake pedal to a force of 5,000 kPa (725 psi). 7. Record the distance displayed on the scan tool that the BMC Primary Piston has travelled at the applied brake pedal force of 5,000 kPa (725 psi). 8. Release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-8 to obtain a second measurement. Page 18095 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 12704 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Page 15353 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 9023 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Page 11591 15. Ensure that the junction block retainers are in the open position (1). 16. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 17. Install the underhood junction block cover. 18. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . Page 7854 Switch Position Icons Page 17635 Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Page 4493 Drive Motor Power Cable: Diagrams Component Connector End Views Drive Motor Battery Cable Terminal Extension Cover (HP2) Drive Motor Battery Current Sensor (HP2) Page 4922 1 - Rear Bumper 2 - Junction Block -Rear Lamps 3 - Data Link Resistor 4 - Trailer Connector (except MEX/EXP) Rear Fram and Underbody Components (10 Series) Page 4680 1. Attach a lifting device (2 and 3) to the drive motor generator control module assembly at the three identified locations. 2. Lift the drive motor generator control module assembly into the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Remove the lifting device and install the ball studs (1). Tighten the ball studs to 10 Nm (89 lb in) . 4. Install the drive motor generator control module assembly retainers (4) and mounting nuts (3). Tighten the mounting nuts to 9 Nm (80 lb in) . 5. Install the APM ground strap (1) and APM ground strap nut (2). Tighten the nut to 9 Nm (80 lb in) . Page 7729 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 14810 Disclaimer Page 18263 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Page 4127 Page 8176 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 11573 1. Install the auxiliary battery negative cable to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Position the auxiliary battery negative cable ground terminal to the left cylinder head and install the bolt and tighten to 25 Nm (18 lb ft) . 3. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . Page 11947 Page 10938 7. Using the J-39544-KIT - set , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer toBrake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction) . 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - washers and the lug nuts. Page 7838 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 18549 Front Center Seat Back Cushion Latch Replacement (AE7) Front Center Seat Back Cushion Latch Replacement (AE7) Page 15103 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Page 19513 Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 18096 Memory Seat Module (MSM) X3 (AN3) Page 3610 Piston Ring: Specifications Piston Rings Piston Ring End Gap - First Compression Ring - Measured in Cylinder Bore Production...............................................0.20-0.41 mm (0.0079-0.0161 in) Piston Ring End Gap First Compression Ring - Measured in Cylinder Bore Service.....................................................0.20-0.46 mm (0.0079-0.0181 in) Piston Ring End Gap Second Compression Ring - Measured in Cylinder Bore Production...........................................0.37-0.69 mm (0.0146-0.0272 in) Piston Ring End Gap Second Compression Ring - Measured in Cylinder Bore Service.................................................0.37-0.75 mm (0.0146-0.0295 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore Production..........................................................0.22-0.79 mm (0.0086-0.0311 in) Piston Ring End Gap - Oil Control Ring - Measured in Cylinder Bore Service................................................................0.22-0.84 mm (0.0086-0.0331 in) Piston Ring-to-Groove Clearance - First Compression Ring Production.........................................................................0.04-0.083 mm (0.0016-0.0033 in) Piston Ring-to-Groove Clearance - First Compression Ring Service..............................................................................0.04-0.083 mm (0.0016-0.0033 in) Piston Ring-to-Groove Clearance - Second Compression Ring Production..................................................................0.035-0.078 mm (0.0014-0.0031 in) Piston Ring-to-Groove Clearance - Second Compression Ring Service........................................................................0.035-0.078 mm (0.0014-0.0031 in) Piston Ring-to-Groove Clearance - Oil Control Ring Production.................................................................................0.013-0.201 mm (0.0005-0.0079 in) Piston Ring-to-Groove Clearance - Oil Control Ring Service.......................................................................................0.013-0.201 mm (0.0005-0.0079 in) Pistons and Pins Pin - Piston Pin Clearance- to-Piston Pin Bore Production...........................................................................................0.002-0.01 mm (0.00008-0.0004 in) Pin - Piston Pin Clearance-to-Piston Pin Bore Service................................................................................................0.002-0.015 mm (0.00008-0.0006 in) Pin - Piston Pin Diameter..................................................................................... ........................................................23.952-23.955 mm (0.9430-0.9431 in) Pin - Piston Pin Fit in Connecting Rod Bore Production.............................................................................................0.007-0.02 mm (0.00027-0.00078 in) Pin - Piston Pin Fit in Connecting Rod Bore Service................................................................................................0.007-0.022 mm (0.00027-0.00086 in) Piston - Piston Diameter - Measured Over Skirt Coating........................................................................................101.615-101.649 mm (4.0006-4.0019 in) Piston - Piston to Bore Clearance Production.................................................................................................-0.031 to +0.021 mm (-0.0012 to +0.0008 in) Piston - Piston to Bore Clearance - Service Limit With Skirt Coating Worn Off...................................................................................0.071 mm (0.0028 in) Page 18505 Seat Recline Position Sensor - Driver (AN3) Page 6850 Page 582 Page 7434 Director, Customer and Relationship Services 09241 Page 12224 Fuse Holder X4 (Engine Chassis Harness) (Diesel) Fuse Holder X4 (Engine Chassis Harness) (Diesel with K76/YF2) Junction Block - Left I/P Electrical Center Identification Views Junction Block - Left I/P, Label Page 18140 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 17938 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Page 8135 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 14273 Tighten the bolts to 12 Nm (106 lb in). Note The power steering assist motor electrical harness connector should engage smoothly as it is pushed on. Do NOT force the electrical connector. 7. Engage the power steering assist motor electrical harness connectors (1) to the electronic power steering control module. 8. Ensure the connector cam lever (3) and the connector cam lever lock tab (2) are fully engaged. The connector in the graphic is shown upside down for clarity. 9. Secure the power steering assist motor electrical harness connector position assurance tab (3). 10. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 11. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 12. Perform the high voltage enabling procedure. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Page 18255 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 12352 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Page 3844 16. For 1500 series vehicles, remove the crossbar bolts/nuts and crossbar. 17. For 2500 series vehicles, remove the crossbar bolts/nuts and crossbar. Page 9762 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 7124 Backprobe Note * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to Page 12064 Fuse Block - Mobile Radio (9L4) Page 1330 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in) . 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) 6. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Page 18468 1 - Door Frame 2 - Outside Rearview Mirror -Driver 3 - Memory/Heated Seat Switch -Driver (AN3) 4 - Door Lock/Window Switch -Driver 5 - Speaker -Left Front 6 - Window Motor -Driver (A31) 7 Inflatable Restraint Side Impact Sensor (SIS) -Left Front (ASF) 8 - Door Latch -Driver Page 20370 Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 11600 6. Remove the underhood junction block cover. 7. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 8. Remove the junction block. Page 880 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 13530 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the Mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Staggering the splices by 65 mm (2.5 in) is recommended. Note Apply the Mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the Mylar tape. If the Mylar tape is damaged, use 3M product AL-36FR to replace the damaged Mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: Page 2184 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 10714 Page 14890 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 19587 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 8563 Pressure Regulating Solenoid: Service and Repair Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the range selector lever cable heat shield bolts (1). 3. Remove the range selector lever cable heat shield (2). 4. Disconnect the range selector lever cable (2) from the range select lever. 5. Remove the range selector lever cable retainer (1). 6. Remove the range selector lever cable (2) from the cable bracket. Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Page 7530 Transfer Case Shift Control Module X3 (NQF/NQH) Page 5072 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 12173 Fuse Block - Auxiliary X1 (HP2) Page 2901 Page 2963 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 867 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) Page 13127 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6322 Variable Valve Timing Actuator: Service and Repair Camshaft Position Actuator Replacement Camshaft Position Actuator Replacement Special Tools * EN 46330 Timing Belt Tensioner Retaining Pin * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pump/Service and Repair) . 2. Remove and discard the camshaft position (CMP) actuator solenoid valve (234). Page 2667 Fuse Block - Auxiliary X2 (HP2) Page 11733 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9577 Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Reference mark the propeller shaft (1), the universal joint strap (2), the universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the rear propeller shaft bolts (3) and the universal joint strap (2). 4. Using a flat bladed tool, remove the clamp (2) securing the boot (3) to the front propeller slip yoke (4) and at the center bearing (1) by prying up the exposed end of the clamp (2). Page 14086 Page 12672 Multiple Junction Connector: Diagrams X400 - X499 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Page 8007 2 - Transfer Case Vent 3 - Transfer Case Input Shaft Seal 4 - Transfer Case Input Shaft Bearing Outer Retaining Ring 5 - Transfer Case Stud 6 - Transfer Case Selector Switch - O-Ring - Seal 7 - Transfer Case Shift Control Switch Assembly 8 - Transfer Case Front Half 9 - Transfer Case Half Locating Pin 9 - Transfer Case Half Locating Pin 10 - Transfer Case Input Shaft Bearing Assembly 11 - Transfer Case Input Shaft Inner Retaining Ring 12 - Transfer Case High/Low Internal Gear 13 - Transfer Case High/Low Internal Gear Retaining Ring 14 - Transfer Case Rear Output Shaft Rear Bearing Outer Retaining Ring 15 - Vehicle Speed Sensor Assembly 16 - Vehicle Speed Sensor O-Ring - Seal 17 - Transfer Case Rear Half 18 - Transfer Case Access Hole Plug 19 - Transfer Case - Harness - Bracket 20 - Transfer Case Half Bolt/Screw (Qty: 17) 21 - Transfer Case Rear Output Shaft Bushing 22 - Transfer Case Rear Output Shaft Seal 23 - Transfer Case Oil Fill Plug 24 - Transfer Case Oil Drain Plug 25 - Transfer Case Front Output Shaft Rear Bearing Assembly 26 - Transfer Case Shift Detent Plunger Plug 27 - Transfer Case Shift Detent Plunger Plug O-Ring - Seal 28 - Transfer Case Shift Detent Spring 29 - Transfer Case Shift Detent Plunger 30 Transfer Case Shift Detent Lever Bearing Assembly 31 - Transfer Case Shift Lever Seal 32 Transfer Case Shift Lever 33 - Transfer Case Control Lever Bolt/Screw 34 - Transfer Case Shift Lever - Rubber - Seal Internal Components Page 11410 6. Install the ABS module splash shield (1). 7. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft) . Page 20333 Page 13498 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 12333 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3675 Drive Belt: Service and Repair Air Conditioning Compressor Belt Replacement Air Conditioning Compressor Belt Replacement (V8) Removal Procedure 1. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (See: Drive Belt Replacement - Accessory) . 2. Remove the skid plate. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Cut the belt (1) from air conditioning (A/C) and crankshaft pulleys. Installation Procedure 1. Position the belt behind the rear face of the balancer (1) and off of the A/C pulley (2). 2. Install the belt installation tool (3) onto the balancer. Page 5089 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 16609 Memory Seat Module (MSM) X4 (AN3) Page 12327 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 2465 same P/N for the same dealer will cost $50 (USD). Part Request Form - Warranty Parts Center IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped. Warranty Information Page 328 Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: All Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 2246 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection ( See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Page 4547 7. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 8. Rotate the drive motor generator control module assembly onto the PIM cover. 9. Remove the APM to PIM mounting fasteners (1). 10. Remove the APM (2) and discard the coolant seal (3). 11. Remove the drive motor generator power inverter coolant pipe bolts (4, 7). 12. Remove the drive motor generator power inverter coolant pipes (5, 8). 13. Remove and discard coolant seals (6, 9). Installation Procedure Page 13189 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Page 13345 Junction Block - Left I/P X2 (except MEX) Page 14716 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 13586 Fuse Block - Underhood X1 Page 4472 Drive Motor Generator Battery Control Module X4 (HP2) Page 20228 Page 20431 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 9718 Page 5931 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5753 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 2701 Page 18246 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 14320 Page 13713 Page 12574 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 13256 Fuse Block - I/P Bottom View Fuse Block - I/P X1 Page 19530 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Special Tools CH-48027 Digital Pressure Gage Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions) . Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (See: Fuel Filter/Fuel Pressure Release/Service and Repair/Fuel Pressure Relief (With CH 48027)) . 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of theCH-48027 , refer to the manufacture's directions. Removal Procedure Page 1761 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 13356 Junction Block - Left I/P X13 (AN3) Page 7046 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Wheels/Tires Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 14659 Page 3804 Allow at least a two hour soak time between engine OFF and start up when evaluating the tick noise. 2. Start the engine and evaluate the valve lifter tick noise. ‹› If the valve lifter tick noise is still present, replace all 16 valve lifters. Refer to Valve Lifter Replacement in SI. Parts Information Note A V8 AFM engine requires 8 AFM lifters and 8 non-AFM lifters for a total of 16 lifters. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Page 13855 Page 11912 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2226 Frame Angle Measurement (Express / Savana Only) ........ Page 9180 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 4942 1 - Fuel Tank Pressure (FTP) Sensor 2 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly -Front 4 - Fuel Pump 5 - Fuel Tank 6 - Electronic Brake Control Module (EBCM) Left Side Frame and Underbody Components (Diesel) Page 2075 Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 7157 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1887 1 - Fuel Injector 2 2 - Turbocharger Vane Position Sensor 3 - Fuel Injector 4 4 - Fuel Rail Pressure (FRP) Sensor 5 - Fuel Injector 6 6 - Fuel Injector 8 7 - Glow Plug 8 8 - Glow Plug 6 9 - Engine Oil Pressure (EOP) Sensor 10 - Engine Oil Level (EOL) Switch 11 - Glow Plug 4 12 - G106 13 - G102 14 - Glow Plug 2 Top of the Engine Components (Diesel) Page 5338 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 10441 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 15491 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Page 6759 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 10315 Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5189 Accelerator Pedal Position Sensor: Connector Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Page 15317 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Procedures Ignition Switch Lock Cylinder: Procedures Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 18754 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 1449 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 1400 Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 3364 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 17237 Body Control Module (BCM) X6 Page 3000 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Page 20871 2. Locate the underhood bussed electrical center (UBEC) (1). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse (1). 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 7 in this section of the bulletin 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 9. Secure the UBEC cover on the UBEC. 10. Close the hood. 11. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 12. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Cadillac CTS 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 3860 Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas Except 4.3L) Page 18 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 11592 Positive: Service and Repair Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Removal Procedure 1. Disconnect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Service and Repair )Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) (See: Service and Repair) . 2. Remove the underhood junction block cover. 3. Open the auxiliary battery positive cable post cover. 4. Loosen the auxiliary battery positive cable nut (2). 5. Remove the auxiliary battery positive cable from the battery positive post. 6. Remove the auxiliary battery positive cable nut (1) from the underhood junction block stud. Page 5322 Spark Plug: Testing and Inspection Spark Plug Inspection * Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications ( See: Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling, replace with a colder plug - Pre-ignition causing spark plug and/or engine damage , replace with a hotter plug * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. * Inspect the insulator (2) for flashover or carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated will cause arcing to ground. * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 13856 Page 12291 Devices and Sensors Page 12326 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro .64) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro .64 connectors. Page 14423 Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Steering Wheel Components Page 3878 of removing the cleaner is cranking engine over. Make sure to unplug the ignition coils and fuel injector before cranking the engine over. Also make sure that the painted surfaces are covered so no damage is done. 4. Remove the oil pan. Refer to Oil Pan Replacement in SI. 5. Remove the AFM valve (1). 6. Install the new shield (1), GM P/N 12639759, and tighten the AFM valve to the oil pan to 28 Nm (20 lb ft). Important Ensure that the engine cleaner is thoroughly removed before reinstalling the spark plugs. Failure to do so may result in a hydro-lock condition. 7. Reinstall the spark plugs. Replace the spark plugs if necessary due to full of carbon. Refer to the parts catalog. 8. Reinstall the oil pan. Refer to the Oil Pan Installation procedure in SI. Replace the oil pan gasket if necessary. Refer to the parts catalog. Replace the engine oil if necessary. 9. Re-evaluate the oil consumption. Document on the repair order. If the oil consumption is still greater than 0.946 L (1 qt) in 3,200 km (2000 mi), replacement of the pistons and rings will be required. Important Page 4231 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 3201 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar and Support Assembly Replacement (Bushing Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist to lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjust nut (4) from the crossmember (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. Page 20976 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 7526 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Wheels/Tires - Module Programming For 20/22 Inch Wheels Engine Control Module: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 10001 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 6074 Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 12383 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12674 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 12436 Page 4553 board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 7. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. 8. Temporarily install the PIM cover (2) with 4 finger-tightened fasteners (1). 9. Rotate the drive motor generator control module assembly onto the PIM cover. 10. Remove the APM to PIM mounting fasteners (1). 11. Remove the APM (2) and discard the coolant seal (3). Installation Procedure Page 11587 9. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 10. Remove the generator battery jumper cable nut (3) from the mega fuse holder. 11. Remove the generator battery jumper cable terminal (2) from the mega fuse stud. 12. Remove the auxiliary battery positive cable from the mega fuse holder. 13. Disconnect auxiliary battery positive cable electrical connector (1) from the auxiliary battery relay. 14. Reposition the auxiliary battery positive cable boot (5). 15. Remove the auxiliary battery positive cable nut (4) and cable from the battery relay. 16. Remove the auxiliary battery positive cable retainer (2) from the stud on the front of dash. 17. Remove the auxiliary battery positive cable push nuts (6). Page 2630 Fuse: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 8863 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 16679 Remote Switch: Locations Instrument Panel/Center Console Component Views Console Components 1 - Rear Seat Audio (RSA) Control (UK6) 2 - Accessory Power Outlet - Center Console (D07) 3 Audio Amplifier (UQA) 4 - Accessory Power Outlet - Center Console Compartment (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Engine - Oil Consumption On Aluminum Block Engines Piston Ring: Customer Interest Engine - Oil Consumption On Aluminum Block Engines TECHNICAL Bulletin No.: 10-06-01-008B Date: March 07, 2011 Subject: Engine Oil Consumption on Aluminum Block Engines with Active Fuel Management (AFM) (Install AFM Oil Deflector and Clean Carbon from Cylinder) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2007-2009 GMC Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2009 Pontiac G8 GT Equipped with Aluminum Block V8 Engine with Active Fuel Management (AFM) (RPOs LC9, LH6, L76, LFA, L92) with Greater than 45,000 km (28,000 mi) Supercede: This bulletin is being revised to add the 2009 model year and new Correction information for the 2009 model year - left rocker arm cover replacement. Information has also been added after step 9. Please discard Corporate Bulletin Number 10-06-01-008A (Section 06 Engine/Propulsion System). Condition Some customers may comment about engine oil consumption of vehicles with higher mileage (approximately 48,000 to 64,000 km (30,000 to 40,000 mi). Verify that the induction system is assembled correctly and that there is no evidence that the engine has been ingesting dirty air due to a mis-assembled induction system. Also verify that the PCV system is functioning properly. If diagnostic procedures indicate that oil consumption is piston /piston ring related, verify that oil consumption is less than 3,000 km (2,000 mi) per liter/quart. If these conditions are met and oil consumption is less than 3,000 km (2,000 mi) per liter/quart, perform the service indicated in this bulletin. Cause This condition may be caused by oil spray that is discharged from the AFM pressure relief valve within the crankcase. Under most driving conditions and drive cycles, the discharged oil does not cause a problem. Under certain drive cycles (extended high engine speed operation), in combination with parts at the high end of their tolerance specification, the oil spray quantity may be more than usual, resulting in excessive deposit formation in the piston ring grooves, causing increased oil consumption. Correction 2009 Vehicles Only Important This left rocker arm cover is NOT to be used on 2007-2008 vehicles because of the calibration of the PCV orifice being different in 2007-2008. A new left rocker arm cover has been released for 2009 engines. Technicians should replace the left rocker arm cover with GM P/N 12642655. This rocker arm cover has relocated PCV drain holes that prevents PCV pullover into the intake manifold. Refer to SI for Valve Rocker Arm Cover Replacement - Left Side. 2008-2007 Vehicles Only To correct this condition, perform the piston cleaning procedure as described in this document, and install a shield over the AFM pressure relief valve per the procedure outlined in this document. Monitor oil consumption after this repair to ensure oil consumption has improved to acceptable levels. If this repair does not correct the condition, it may be necessary to replace the piston assemblies (piston and rings) with new parts. Important It is critical in this cleaning process that the engine/fuel injector cleaner remain in the cylinders for a minimum of 2.5 hours to fully clean the components. The cleaner solution must be removed before a maximum of three hours. 1. Verify the oil consumption concern following Corporate Bulletin Number 01-06-01-011F. If oil consumption is found, continue on with this bulletin. 2. Remove the spark plugs and ensure that none of the pistons are at top dead center (TDC). 3. Clean the pistons by putting 118-147 ml (4-5 oz) of Upper Engine and Fuel Injector Cleaner, GM P/N 88861802 (in Canada, use 88861804), in each cylinder. Allow the material to soak for at least 2.5-3.0 hours, but no more than three hours and then remove the cleaner. A suggested method Page 18814 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7252 Page 9131 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 14785 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 7113 Devices and Sensors Page 15401 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair) . 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair) . 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair) . Page 8099 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 19504 Audible Warning Device Control Module: Diagrams Component Connector End Views Chime Module (UL5) Page 7289 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 6303 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Page 15950 Page 749 Engine Control Module (ECM) X2 (HP2) Page 19383 Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 19357 Page 1842 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Page 18871 Heated/Cooled Seat - Passenger - (KB6) Page 7984 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. Page 10069 6. Using a small pry bar, move the inner seal race forward on the front output shaft. 7. Remove the inner seal race from the front output shaft. 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Remove the remaining part of the output shaft seal from the transfer case. Installation Procedure Page 1423 1. Apply sealant to the threads of the NEW oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Using J 41712 or equivalent, install the oil pressure sensor (706) and washer (707). Tighten the sensor to 35 Nm (26 lb ft). 3. Connect the engine harness electrical connector (1) to the oil pressure sensor. Tighten the sensor to 35 Nm (26 lb ft). 4. Install the intake manifold. Refer to Intake Manifold Replacement (Except LH6, LMG, LY5, L76, LY2, LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LH6, LMG, LY5 and L76) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (LY2 and LY6) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair) . Specifications Firing Order: Specifications Ignition System Specifications Component Locations Auxiliary Battery Relay: Component Locations Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 12170 Fuse: Application and ID Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 13235 Junction Block - Right I/P Electrical Center Identification Views Junction Block - Right I/P, Top View Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 16332 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. Total Fuel Saved (Hybrid) Fuel Saved Over Lifetime shows how much fuel (by volume) was save by driving the Hybrid versus the non-Hybrid (if equipped). This value constantly accumulates over the life of the vehicle and is not re-settable. Fuel Saved Since Reset The Fuel Saved Since Reset is similar to the Fuel Saved Over Lifetime but is re-settable by the driver. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the DIC Vehicle Info switch. Trip Odometer The trip odometer can be accessed through the DIC Trip/Fuel switch function. The trip odometer shows the current distance traveled in either miles or kilometers since the last reset of the trip odometer. The trip odometer can be reset to zero by pressing the set/reset button while the trip odometer is displayed. The trip odometer has a feature called the retro-active reset. This can be used to set the trip odometer to the number of miles (kilometers) driven since the ignition was last turned on. This can be used if the trip odometer is not reset at the beginning of the trip. To use the retro-active reset feature, press and hold the set/reset button for at least four seconds. The trip odometer will display the number of miles (mi) or kilometers (km) driven since the ignition was last turned on and the vehicle was moving. Once the vehicle begins moving, the trip odometer will accumulate mileage. Language The DIC is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Compass The driver information center (DIC) displays the compass based on serial data message from the BCM. The compass module communicates with the body control module (BCM) through a bi-directional data circuit. The instrument panel cluster (IPC) receives compass information from the BCM via the serial data circuit. The compass is displayed in the DIC with other vehicle information and is at the bottom line of the DIC. The compass display shows "- -" when a malfunction is present with the compass module or a compass serial data communication fault exists. The compass displays 'CAL' or 'C' when the compass needs to be calibrated. Cycle the ignition before performing the compass magnetic variation adjustment procedure. Check that the compass module is properly installed in the vehicle since this may cause the compass to malfunction. The embossed arrow on the top of the compass module should be parallel to the centerline of the vehicle. Outside Air Temperature The Outside Air Temperature is sent via the serial data circuit from the BCM to the IPC. It is displayed in the lower left corner of the DIC. It is displayed in the English and Metric units Page 7359 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 13019 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 13404 Component Parts Page 18475 Memory Seat Module (MSM) X5 (AN3) Service Precautions Valve Spring: Service Precautions Valve Springs Can Be Tightly Compressed Warning Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Page 7150 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8283 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 19632 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 14422 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Page 12461 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Page 2822 Page 16006 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 17006 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12171 Fuse Block - Auxiliary (HP2), Top View Page 12125 Page 19826 Fuel Pump and Sender Assembly - Rear (LY6 with MEX without NQZ) Page 8087 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 7127 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics) . Page 2991 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12426 Fuse Block - Mobile Radio (9L4) Page 13422 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 2768 Page 1003 TEHCM Programming Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after October 6, 2009 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided. For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal. 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming. 2. Perform sequential programming event. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 1. Connect the MDI to the vehicle. Use a wire connection with MDI for this programming event. DO NOT use the MDI wireless option. 2. Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen. 3. Select SEQ EBCM/HCP/ECM/TCM/BECM Sequential Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. 4. Follow the on-screen instructions. 3. Using the MDI and Tech 2(R), clear all DTCs if required. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a claim using the table below. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program Page 12699 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Page 521 Page 17474 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 9095 Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Note Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs Caution: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation) . GMLAN Connector Terminal Repair Page 11295 Page 7308 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 4406 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 17226 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P X4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Behind the I/P Components (C67/C42) Page 12265 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chassis Harness Routing (LY6/LMM except 31 Series) Page 8447 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Parking Brake Release Handle Assembly Replacement Parking Brake Lever: Service and Repair Parking Brake Release Handle Assembly Replacement Parking Brake Release Handle Assembly Replacement Page 7324 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 8123 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 6601 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Page 10770 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer . 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair) . 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles))Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair/Removal and Replacement/Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle)) . 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement) . 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 5213 1 - Turbocharger Vane Position Control Solenoid Valve 2 - Glow Plug Control Module (GPCM) 3 Fuel Temperature Sensor 4 - Intake Air Temperature (IAT) Sensor 2 Connector 5 - X128 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Generator - Auxiliary (K76/YF2) 8 - A/C Compressor Clutch (C67/CJ2) 9 - Engine Coolant Temperature (ECT) Sensor 10 - Camshaft Position (CMP) Sensor 11 - X127 12 - Generator 13 - Manifold Absolute Pressure (MAP) Sensor 14 - Intake Air Heater (IAH) 15 - Intake Air Temperature (IAT) Sensor 2 16 - Fuel Heater 17 - A/C Low Pressure Switch (C67/CJ2) Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Steering Column Components 1 - Turn/Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Driver Shift Request Switch (MYC/MYD/MW7) 4 - Automatic Transmission Shift Lever (M30/MYC/MYD/MW7) 5 - Tow/Haul Switch (M30/MYC/MYD/MW7) 6 - Steering Angle Sensor (JL4) 7 - Automatic Transmission Shift Lock Control Solenoid 8 - Theft Deterrent Module (TDM) 9 - Ignition Switch 10 - Inflatable Restraint Steering Wheel Module Coil Page 11870 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 1621 Page 4121 Page 3848 5. Install 1 oil pan bolt into a oil pan bolt hole and up through the gasket. 6. Position and install the oil pan and the rest of the oil pan bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Tighten the oil pan bolts. * M6-Tighten the bolts to 12 Nm (106 lb in). * M8-Tighten the bolts to 25 Nm (18 lb ft). 8. Install the 2 lower transmission bolts (1) until snug. Tighten the bolts to 50 Nm (37 lb ft). 9. Install the air conditioning (A/C) compressor bracket bolts (1). Tighten the bolt to 50 Nm (37 lb ft). Page 7807 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Brakes - Feel Grabby or Touchy DTC C012E Reprogramming Electronic Brake Control Module: All Technical Service Bulletins Brakes - Feel Grabby or Touchy DTC C012E Reprogramming TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 19456 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Page 2653 Fuse: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Page 1676 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 6223 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 8094 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2774 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 12321 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 4495 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Page 14025 Disclaimer Page 755 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 12052 Fuse Block - I/P X3 Drive Motor Generator Control Module Sight Shield Replacement Drive Motor Control Module: Service and Repair Drive Motor Generator Control Module Sight Shield Replacement Drive Motor Generator Control Module Sight Shield Replacement Removal Procedure 1. Remove the fender brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . Note Removing the sight shield disengages the High Voltage Interlock Circuit (HVIC). The sight shield mounting fastener must be installed and properly tightened for the HVIC to be closed. Failure to properly tighten the sight shield mounting fastener may result in an open HVIC condition and DTCs. 2. Loosen the sight shield mounting fastener (1) and lift the sight shield from the ball studs (2). Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 3. Perform the High Voltage Disabling procedure. Refer to High Voltage Disabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . Installation Procedure Page 7256 Page 8435 Director, Customer and Relationship Services 09241 Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 8. Install the fill plug and tighten to 33 Nm (24 lb ft) . 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Page 13154 Fuse Block - Underhood X3 Page 11077 Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Page 8759 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 8083 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 16611 Memory Seat Module (MSM) X6 (AN3) Page 10430 A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Specifications Shift Solenoid: Specifications Shift Solenoid Valve State and Gear Ratio Page 16799 Disclaimer Page 8250 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4899 A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 18763 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 7225 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 6575 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Page 12716 Page 11830 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 4003 11. Position the NEW engine front cover gasket (503) and front cover (502) to the engine. 12. Install the front cover bolts (501) until snug. Do not overtighten. 13. Install the oil pan-to-front cover bolts (1) finger tight. Do not over tighten. Page 6119 1 - Output Speed Sensor (OSS) (M99) 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Transmission Power Inverter Module (3 Phase) Cable Cover 5 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 Page 13766 X300 Engine Harness to Chassis Harness (HP2) Page 8669 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 9814 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 609 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) to locate the electrical center where the relay exists. Note * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 11939 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2964 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 10503 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 4059 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions) . Warning: Refer to Relieving Fuel Pressure Warning (See: Fuel Pressure/Service Precautions) . 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Diagrams/Connector Views) . 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 9251 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Page 472 Page 770 and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Engine running, command the powertrain relay ON and OFF, with a scan tool, while observing the following powertrain relay coil control circuit status parameters. * Powertrain relay coil control Ckt. Short Gnd Test Status * Powertrain relay coil control Ckt. Open Test Status * Powertrain relay coil control Ckt. Short Volts Test Status Each parameter should toggle between OK and Not Run or Not Run and OK 4. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate ON for at least one test point of each fuse. 5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing Important: You must perform the Circuit/System Verification first. 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for DTC P254F. 3. Ignition OFF, disconnect the powertrain relay. 4. Ignition ON, verify that a test lamp illuminates between the powertrain relay coil B+, and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the battery positive cable to the underhood fuse block. 5. Ignition OFF, verify that a test lamp does not illuminate between the powertrain relay coil B+ circuit and the control circuit. ‹› If the test lamp illuminates, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. 6. Remove the test lamp. 7. Ignition ON, command the powertrain relay ON, with a scan tool. Verify with a scan tool that the powertrain relay Ckt. Short Volts Test Status parameter is OK. ‹› If not the specified value, test the control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 8. Test the coil side of the powertrain relay for 65-110 ohms. ‹› If not within the specified value, replace the relay. 9. Ignition OFF, disconnect the ECM X1 connector. 10. Test the powertrain relay control circuit for an open/high resistance. ‹› If the circuit tests normal, replace the ECM. 11. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 12. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground, or an open/high resistance. If the circuits test normal, and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 13. Connect a 20 A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 14. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Page 2879 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 13485 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11186 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7832 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Page 12249 Junction Block - Right I/P X4 Page 13481 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 18758 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6799 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 10685 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in) . 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Battery Charging) 6. Install a scan tool to the vehicle. Note The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Charging System - Volt Meter Fluctuation Information Volt Meter Gauge: Technical Service Bulletins Charging System - Volt Meter Fluctuation Information INFORMATION Bulletin No.: 07-06-03-009B Date: February 05, 2010 Subject: Information on Voltmeter Gauge Fluctuation Due to Regulated Voltage Control System and Concerns About Camper/Trailer Battery Charging Models: 2005-2010 Cadillac Escalade Models 2005-2010 Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2005-2010 GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 07-06-03-009A (Section 06 - Engine/Propulsion System). Voltmeter Fluctuation Condition Some customers may comment that the voltmeter is fluctuating between 12 and 14 volts on their full size pickup or utility vehicle. Starting with the 2005 model year, light duty full size pickups and utilities are equipped with a Regulated Voltage Control (RVC) system. This system reduces the targeted output of the generator to 12.6-13.1 volts when in "Fuel Economy Mode" to improve fuel economy. The generator may exit "Fuel Economy Mode" if additional voltage is required. This will cause the voltmeter to fluctuate between 12 and 14 volts as opposed to non-regulated systems that usually maintain a more consistent reading of 14 volts. This fluctuation with the RVC system is normal system operation and NO repairs should be attempted. Camper/Trailer Battery Charging Concerns Some customers may comment that when towing or hauling a camper/trailer, the auxiliary battery for the camper/trailer will not stay charged. In most cases, this concern is blamed on the new RVC system. While the RVC system does reduce the generator's targeted output voltage to 12.6-13.1 volts when in "Fuel Economy Mode", this feature is bypassed if the tow/haul feature is enabled. With the tow/haul feature enabled, the RVC system will stay in "Charge Mode" and the targeted generator output voltage will be 13.9-15.5 volts, depending on the battery state of charge and the estimated battery temperature. To keep the generator in the "Charge Mode", use either of the following two methods. - The first method is to use the tow/haul mode when towing or hauling a camper or trailer. - The second method is to turn on the headlights, which will increase the generator's targeted output voltage to 13.9-14.5 volts. Disclaimer Page 17162 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (1500) Removal Procedure 1. Turn the ignition switch to the OFF position. Note Do not remove the spare wheel hoist. 2. Remove the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 3. Disconnect the trailer brake control relay electrical connector. Note It is not necessary to completely remove the bolts. 4. Loosen, but do not remove, the trailer brake control relay bolts (1). Page 6750 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) . 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 20160 License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement (VF7) Rear License Plate Lamp Replacement (VF7) Page 20502 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure Page 18872 Page 8068 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 13018 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 17704 Skid Plate: Service and Repair Engine Shield Replacement Engine Shield Replacement Page 8071 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 10153B Date: 100720 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 10153B Date: July 20, 2010 Subject: 10153A - Heated Windshield Washer Module Short Circuit - Permanently Disable and Remove Module Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2009 HUMMER H2 2007-2009 Saturn OUTLOOK Equipped with Heated Washer Fluid System (RPO XA7/CHW) Supercede: This bulletin is being revised to include a note in the service procedure for dealers to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. A T labor code for customers who refuse to have the recall performed. This labor code will NOT close the recall. If a customer refuses to have the recall performed, dealers are to provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. Request that the letter be placed in the vehicle glovebox for future reference by subsequent owners. If at a later date the customer, or a new owner, decides to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. A clarification in the Q&A; regarding proof of vehicle ownership. Please discard all copies of bulletin 10153A, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW). A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. Correction Dealers/retailers are to permanently disable and remove the heated washer fluid system and compensate the customer for the loss of the feature. Vehicles Involved Involved are certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW), and built within these VIN breakpoints: Page 13151 Fuse Block - Underhood X2 Locations Power Window Relay: Locations Passenger Compartment/Roof Component Views Rear of the Passenger Compartment Components 1 - Information Center Telltale Assembly (UD7) 2 - Sliding Rear Window Open Relay (A48) 3 Sliding Rear Window Close Relay (A48) 4 - Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) 5 - Sliding Rear Window Motor (A48) Page 7306 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Release the lower wire dress cover locking tab. Page 14983 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Install the blower motor insulating cover screws and tighten to 1.6 Nm (14 lb in) . 6. If equipped, install the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Page 17663 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 18309 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Crew Cab) Sunroof Motor/Actuator Replacement (Crew Cab) Page 1824 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 14915 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 20906 Notice to Customer General Motors released this product recall in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act because a defect that relates to motor vehicle safety exists in your vehicle. It was implemented to address the potential consequences of a printed circuit board electrical short within the Heated Washer Fluid System (HWFS). The significance of this failure can vary from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. This failure can occur at any time, even when the vehicle is unattended - parked and key not in the "ON" position. Note that a resulting under hood fire could also involve other nearby vehicles or structures. Performance of this recall procedure will allow your GM dealer to eliminate these risks by permanently removing the HWFS from your vehicle. In addition to the risk of a thermal incident, including a fire, it is possible that the HWFS will become inoperative at a future time. If this occurs, it will not be repaired or replaced by GM. Note that GM does not endorse or otherwise approve the Page 10000 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1522 Drive Motor Generator Battery Control Module X3 (HP2) Page 11657 J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14491 Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Page 5843 Page 20890 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Page 1731 Crankshaft Position (CKP) Sensor (Diesel) Page 13603 Fuse Block - I/P X2 (except MEX) Page 5085 Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Page 4620 Drive Motor Generator Battery Control Module X2 (HP2) Page 5805 Serial Data Gateway (SDG) Module (HP2) Page 18034 Keyless Entry Transmitter: Service and Repair Remote Control Door Lock Transmitter Programming Next Available Slot Note * On some vehicles, keyless entry transmitters may also be programmed using the driver information center (DIC). Refer to the vehicle owners manual for information. * All transmitters which are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle are not learned at this time, they will become inoperative and require additional programming. * Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. This procedure will program keyless entry transmitters in sequential order. If two transmitters are currently learned to the vehicle as transmitters 1 and 2, using this procedure will learn the next transmitter are transmitter 3, and so on. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. 2. Select Next Available Slot. The vehicle chime will sound two times to indicate programming mode has been entered. Follow the on-screen instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm the programming. 3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF, exit the vehicle, and operate the transmitter functions in order to verify correct system operation. Invalidate All Fobs Note * On some vehicles, keyless entry transmitters may also be programmed using the driver information center (DIC). Refer to the vehicle owners manual for information. * All transmitters which are to be recognized by the remote control door lock receiver (RCDLR) must be programmed in a single programming sequence. Once the Invalidate All Fobs selection is made, all learned transmitters are erased. If all the existing transmitters associated with the vehicle are not learned at this time, they will become inoperative and require additional programming. * Do not operate or program the transmitters in the vicinity of other vehicles that are in the keyless entry program mode. This prevents the programming of the transmitters to the incorrect vehicle. This procedure will first erase all known keyless entry transmitters. After all transmitters are erased, the procedure will begin to program keyless entry transmitters in sequential order, beginning with transmitter 1. 1. With a scan tool, access the Remote Control Door Lock Receiver Module Setup menu. Select Program Key Fobs. 2. Select Invalidate All Fobs. This will erase all learned transmitters and prepare the RCDLR to learn new transmitters. Follow the on-screen instructions. After each transmitter has been programmed, the vehicle chime will sound to confirm the programming. 3. When all the desired transmitters have been programmed, cycle the ignition from ON to OFF, exit the vehicle, and operate the transmitter functions in order to verify correct system operation. Transmitter Slot Programming Note The keyless entry transmitter used in the Advance 2 Way Remote Start System is unique to the system. When servicing or replacing a transmitter, ensure that the correct transmitter is used. The correct transmitter part number can be found in the Accessory section of the parts catalog. Attempting to replace an Advance 2 Way Remote Start transmitter with a regular service part may result in a failure to program the transmitter. Transmitter slot programming allows a single transmitter to be programmed into a specific slot without affecting any of the other programmed transmitters. By using slot programming, the transmitter originally programmed to a specific slot is erased and the new transmitter learned in its placed. 1. Install a scan tool. 2. Turn ON the ignition with the engine OFF. 3. With the scan tool, select Body. 4. Select Remote Control Door Lock Receiver (RCDLR). 5. Select Module Setup. 6. Select Program Key Fobs. 7. Select the key fob desired to be programmed. 8. Follow the scan tool on screen instructions. Page 5108 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (4) to knock sensor. 3. Position the engine wiring harness sleeve (3) over the knock sensor electrical connection. 4. Install the left front wheel and tire. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Page 5249 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 13653 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7093 7. Remove the range selector lever nut (1). 8. Remove the range selector lever (2). Installation Procedure 1. Install the range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the range selector lever nut (1). Tighten the nut to 25 Nm (18 lb ft). Page 17102 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Removal Procedure 1. Beginning at the joint located in the center rear of the lace of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track . Installation Procedure 1. Position the end of the sunroof finishing lace at the center rear of the sunroof opening. Page 7558 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 17276 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement Rear Bumper Impact Bar Brace Replacement Page 14312 Page 13279 Fuse Block - Underhood X4 Page 7414 Clutch Components 1 - Transfer Case Rear Output Shaft 2 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 3 - Transfer Case Control Lever 4 - Transfer Case Control Actuator Lever Bearing Assembly 5 - Transfer Case Control Actuator Lever Ball (Qty: 3) 6 - Transfer Case Control Actuator Lever Assembly 7 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 8 - Transfer Case Control Actuator Lever Washer 9 - Transfer Case Four Wheel Drive Clutch Pressure - Apply Plate Page 3459 1. Pressurized oil enters the advance cavities (1) of the actuator and moves the park pin (3) from the locked position. 2. As pressure increases within the advance cavities (1), the rotor and camshaft rotate clockwise advancing valve timing. 3. As the duty cycle decreases, the spool is repositioned and oil is sent to the retard cavities (2), rotating the rotor and camshaft counter clockwise, retarding valve timing. * With a 0 percent duty cycle signal to the magnet, the spool is positioned in the fully extended position and there is full flow to the retard cavities of the actuator. As duty cycle increases to near 50 percent, flow to the retard cavities is decreased. * With a 50 percent duty cycle, the spool is positioned neutral, with no flow to either the advance and retard cavities. * With a 51-100 percent duty cycle, the spool is positioned to provide oil flow to advance cavities. As the duty cycle increases, the flow to advance cavities increases. * With a 100 percent duty cycle, there is full flow to the advance cavities of the actuator. * The above duty cycle percentage values are only a guideline, as the actual duty cycle values may vary based on engine oil temperature, solenoid magnet coil temperature, magnet coil resistance, and other specifics. CMP Actuator Park Position Verification Page 10627 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft Position Switch Replacement Power Brake Booster Replacement (Non-Adjustable Pedals) Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Vacuum Sensor Replacement Page 15355 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Page 16996 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Resistor Left (HP2) 3 - Horn - Right (7Z1/YE9/HP2) 4 - Generator Control Module Temperature Sensor (HP2) 5 - A/C Low Pressure Sensor (HP2) 6 - Ambient Air Temperature Sensor (CJ2/C67)) 7 - Hood Ajar Switch (AP3/AP8) 8 Horn - Left 9 - Inflatable Restraint Front End Sensor - Left 10 - High Voltage Circuit Impact Detection Sensor (HP2) 11 - Inflatable Restraint Front End Sensor - Right 12 - Engine Cooling Fan Resistor - Right (HP2) 13 - Engine Cooling Fan - Right 14 - Generator Control Module Coolant Pump - Right (HP2) 15 - Generator Control Module Coolant Pump - Left (HP2) Page 17048 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in) . 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Brakes - Grabby/Touchy Or DTC C012E Stored Electronic Brake Control Module: Customer Interest Brakes - Grabby/Touchy Or DTC C012E Stored TECHNICAL Bulletin No.: 09-05-22-003 Date: April 29, 2009 Subject: Brakes Feel Grabby/Touchy When Applied or Check Engine Light On, DTC C012E (Reprogram EBCM) Models: 2009 Cadillac Escalade 2009 Chevrolet Silverado, Tahoe 2009 GMC Sierra, Yukon All Equipped with Two-Mode Hybrid System (RPO HP2) Condition Some customers may comment that the brakes are grabby or touchy when applied or an intermittent MIL/SES light may be illuminated. Upon further investigation, the technician may find DTC C012E set in the EBCM and C12FE set in the ECM. Correction A revised calibration has been released to address this condition. Technicians are to reprogram the EBCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Reflash the brake control module. Refer to Electronic Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Transmission Speed Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 2814 Fuse Block - Underhood X5 Page 4707 Page 9306 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Navigation Radio - Map Disc Read Error Message Displayed Navigation Module: Customer Interest Navigation Radio - Map Disc Read Error Message Displayed TECHNICAL Bulletin No.: 10-08-44-001B Date: May 04, 2010 Subject: "Checking The Map DVD" Message Displayed (Update Navigation Radio Software) (U.S. and Canada Only) Models: 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2009 HUMMER H2 Equipped With Navigation Radio RPO UVB or U3U Attention: This software update requires the engine to be RUNNING with the gear selector in PARK. Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 10-08-44-001A (Section 08 - Body and Accessories). Condition Some customers may comment that a "Checking The Map DVD" message is displayed. Cause This condition may be caused by a software anomaly. Correction Important Before proceeding with the update, advise the customer that the Address Book, Previous Destination data and Preset data are removed during the SW update. The user will have to input this data when the update is complete. - Do not eject the disc during the update. - Do not leave the disc in the radio after the update. - Do not give the disc to the customer. - The software update disc may be used to update more than one vehicle. Navigation Software Update Procedure Use the following procedure to update the Navigation Radio software using the Navigation Radio Software Update Disc P/N 20946039. The software update disc is to be obtained from the WPC using the Part Request Form - Warranty Parts Center information below. Important - This software update disc can only be used to update the navigation radios specified in this bulletin. DO NOT use this software update disc to update any other vehicle's navigation radio. The map DVD will be needed to verify proper system operation after the software update has been performed. This software update requires using the map DVD slot. The update WILL NOT work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Wear latex gloves while performing the software update, to avoid fingerprints on the discs and the radio. Note DO NOT stop the engine until all tasks are completed. The software update MUST BE performed with the engine RUNNING and the gear selector position in PARK. IF the vehicle is turned off PRIOR TO the software update being completed, the process may not work again and a new Navigation Radio may be Page 2654 Fuse Block - I/P Top View Page 6630 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Page 7927 Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 17054 Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 9367 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities andAdhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) . 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Page 10856 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Restraints - Information on DTC B0081 5A Air Bag Control Module: All Technical Service Bulletins Restraints - Information on DTC B0081 5A INFORMATION Bulletin No.: 08-09-41-009A Date: February 03, 2009 Subject: Information on DTC B0081 5A Models: 2009 Cadillac Escalade (Including Hybrid), Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado (including Hybrid), Suburban, Tahoe 2009 GMC Sierra (including Hybrid), Yukon (Including Hybrid), Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 Pontiac G8 Supercede: This bulletin is being revised to update the models to include full size trucks. Please discard Corporate Bulletin Number 08-09-41-009 (Section 09 - Restraints). Technicians may find a DTC B0081 5A in some of the vehicles listed above. The sensing and diagnostic module (SDM) is setting this DTC due to an issue with the messages in the software for the SDM. Technicians should check for DTCs while the ignition is in RUN. If DTC B0081 5A is set in history, there is no need for any parts replacement. The only way this code is set in history is if the key is left in ACC for more than 10 seconds. The passenger side tell tale airbag light in the cluster will stay on solid until the key is in RUN or OFF. For example, the customer will have the car parked, key in ACC and listening to the radio the light comes on and the DTC B0081 5A sets. If you are checking the vehicle after this event, you will find DTC B0081 5A in history if the IGN is in RUN. If you turn the key to the ACC position for more than 10 seconds with the Tech 2(R) tool connected, the code will be current as long as you are in the ACC position. If the key is moved to RUN or OFF, the telltale light will go off and the code will go immediately to history (reference to PIC4917 DTC B0081 5A In History). This condition will only occur with the following passenger presence system (PPS) module part numbers: ^ 25977948 (CK) (All) ^ 94216444 (G8) (Leather) ^ 92221553 (G8) (Leather) ^ 92219364 (G8) (Cloth) Remember that any time the vehicle is brought into service that the customer could have operated the vehicle in ACC for more than 10 seconds. This will cause the passenger side airbag light to come on solid in the cluster. Please tell the customer that this is a normal operating characteristic. If DTC B0081 5A is current while the ignition is in RUN, please check all connections and wiring. Check the seat connector located on the right side under the sill plate in the door opening. Pull the seat out of the vehicle and check for PPS wiring and make sure all connectors are connected. ThePPS Module has two connections one for the seat harness and one for the sensor mat (the sensor mat is located between the seat foam cushion and seat pan). If other DTCs are current, follow the diagnostics in SI. (There are two SDM DTC s related to PPS: B0081 71 - Passenger Presence System 1 Invalid Serial Data Received and U0170 - Lost Communication With Restraints System Sensor A (PPS)). Disclaimer Page 13053 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 13808 X110 Inline Harness Connector End Views X110 Engine Harness (Except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH) Page 10337 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 11683 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2992 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 642 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right Right Side of the I/P Components Page 13538 Page 12540 For vehicles repaired under warranty, use the table. Disclaimer Page 5007 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (6.0L/6.2L) Camshaft Position (CMP) Sensor (4.3L) Page 5324 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. If replacing the right side spark plug(s), remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) , and remove the right side plug(s) through the wheel opening. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 2. If replacing the right side spark plug(s), perform the service disconnect. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 3. Remove the spark plug wire from the spark plug. 1. Twist the spark plug wire boot a 1/2 turn. 2. Pull only on the boot in order to remove the wire from the spark plug. Page 20687 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 9078 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 12879 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 19655 Compass: Description and Operation Compass Calibration and Magnetic Variance Compass Calibration The compass direction will show CAL if it needs to be calibrated. Before calibrating the compass, drive the vehicle to an area that is magnetically clean (free of large metallic objects). 1. Turn ON the ignition. 2. Before calibrating the compass, make sure the compass is set to the variance zone in which the vehicle is travelling. See Compass Magnetic Variation Adjustment below. 3. Press the vehicle information button until the PRESS TO CALIBRATE COMPASS screen is displayed. 4. Press the set/reset button to start the compass calibration. 5. The DIC will display CALIBRATING: DRIVE IN CIRCLES. Drive the vehicle in circles at less than 8 km/h (5 mph) to complete the calibration. The DIC will display CALIBRATION COMPLETE when the calibration is complete. Compass Magnetic Variation Adjustment Compass variance is the difference between the earth's magnetic north and true geographic north. If not adjusted to account for compass variance, the compass in the vehicle could give false readings. Under certain circumstances, such as during a long distance cross-country trip, it will be necessary to compensate for compass variance and reset the zone through the DIC. World Magnetic Variation Map 1. Locate your geographic location. Refer to the variation zone map. 2. Turn ON the ignition with the engine OFF. 3. Press the vehicle information button until PRESS TO CHANGE COMPASS ZONE displays on the DIC. 4. Press the set/reset button to scroll through and select the appropriate variance zone. 5. Navigate to one of the trip/fuel menu screens to view the direction the vehicle is moving. This will be shown in the top right corner of the DIC display. If the compass needs to be calibrated, use the compass calibration procedure above. Procedures Throttle Body: Procedures Throttle Learn Throttle Learn Description The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure With Scan Tool - Reset Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * Ignition ON, engine OFF. * The vehicle speed sensor (VSS) is 0 km/h (0 mph). Without Scan Tool - Learn Procedure * DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool - Reset Procedure 1. Ignition ON, engine OFF, with a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool - Learn Procedure Important: Do NOT perform this procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) . 1. Start and idle the engine in PARK for 3 minutes. 2. With a scan tool, monitor desired and actual RPM. 3. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 4. Ignition OFF for 60 seconds. 5. Start and idle the engine in PARK for 3 minutes. 6. After the 3 minute run time the engine should be idling normal. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 7. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft) . Locations Braking Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (M30/M70/MW7) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Left Rear of the Engine Compartment Components (Except HP2) Page 7902 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems) . 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages () . Page 9474 Note In steps 3 and 4, pull out on the axle shaft after the lock has been installed to ensure that the lock is seated properly. 3. Install the lock (1) in the rear axle (2), without a locking differential. 4. Install the lock (1) on the rear axle shaft (3), with a locking differential. Page 17131 1 - Trailer Brake Control Relay (JL1) 2 - Trailer Brake Control Module (JL1) 3 - Trailer Connector (Except MEX/EXP) 4 - Fuel Pump Flow Control Module 5 - Data Link Resistor (Except LU3/LY6) Rear Frame and Underbody Components (20/30 Series) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Page 12721 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (A48) Page 9430 necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle))Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair/Removal and Replacement/Front Drive Axle/Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles)) . Page 6933 Intake Air Valve (Diesel) Page 18737 Devices and Sensors Page 7120 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Voice Recognition System - Won't Recognize Bluetooth(R) Communications Control Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Power Brake Booster Replacement (Non-Adjustable Pedals) Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Vacuum Sensor Replacement Page 3750 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations . 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Page 4458 12 - Drive Motor Battery Current Sensor Assembly 13 - Drive Motor Generator Battery Current Sensor Bracket 14 - Drive Motor Battery Current Sensor Bolt 15 - Drive Motor Generator Battery Control Module Assembly 16 - Drive Motor Battery Control Module Bracket 17 - Drive Motor Battery Control Module Bracket Bolt 18 - Battery Cable Clip 19 - Drive Motor Battery Control Module Bracket Bolt 20 - Drive Motor Battery Control Module Bracket 21 - Drive Motor Battery Positive and Negative Cable Bolt 22 - Drive Motor Battery Positive and Negative Cable Assembly 23 - Battery Front Cover Retainer 24 - Drive Motor Battery Front Cover Assembly 25 - Drive Motor Battery Front Cover Bolt 26 - Battery Terminal Cover 27 - Battery Terminal Cover 28 - Battery Terminal Cover 29 - Drive Motor Battery Cooling Air Outlet Duct Seal 30 - Drive Motor Battery with Case 31 - Drive Motor Battery Cooling Air Outlet Duct Seal 32 - Drive Motor Battery Current Limit Resistor Nut 33 Drive Motor Battery Inverter Current Limit Resistor 34 - Drive Motor Battery Cable Terminal Nut 35 - Drive Motor Battery Positive High Voltage Contactor Relay Assembly 36 - Drive Motor Battery Wire Harness Connector Retainer 37 - Drive Motor Battery Power Inverter Current Limit Relay Assembly 38 - Drive Motor Battery Positive High Voltage Contactor Relay Nut 39 - Drive Motor Battery Positive Relay Nut 40 - Drive Motor Generator Battery Positive Relay Insulator Nut 41 Drive Motor Generator Battery Positive Relay Insulator Assembly 42 - Drive Motor Battery Sensor Bracket Bolt 43 - Drive Motor Battery Cable Terminal Extension Cover 44 - Drive Motor Battery Terminal Block Cover Nut 45 - Drive Motor Battery Terminal Extension Cable Bolt 46 - Drive Motor Battery Terminal Block Nut 47 - Drive Motor Battery Cable Terminal Extension 48 - Drive Motor Battery High Voltage Manual Disconnect Knob Housing 49 - Drive Motor Battery Cover Terminal Bolt 50 - Battery Cable Terminal Retainer 51 - Drive Motor Battery High Voltage Manual Disconnect Lever Assembly 52 - Drive Motor Battery Disconnect Switch Nut 53 - Battery Disconnect Switch Cable Assembly 54 - Drive Motor Battery Cable Nut 55 - Battery Positive and Negative Cable Cover 56 - Drive Motor Battery Cooling Air Outlet Duct Seal 57 - Drive Motor Generator Battery Ground Bolt 58 - Drive Motor Generator Battery Mounting Nut 59 - Battery Terminal Cover 60 - Battery Terminal Cover 61 - Drive Motor Battery Rear Cover Bolt 62 - Drive Motor Battery Rear Cover Assembly 63 - Drive Motor Generator Battery Ground Nut 64 - Drive Motor Battery Cooling Air Outlet Duct Seal 65 - Drive Motor Generator Battery Retainer Nut 66 Drive Motor Generator Battery Negative Relay Bracket Nut 67 - Drive Motor Generator Battery Negative Relay Bracket 68 - Drive Motor Battery Negative Relay Bracket Bolt 69 - Drive Motor Battery Negative High Voltage Contactor Relay Assembly 70 - Drive Motor Battery Negative Relay Cable Assembly 71 - Drive Motor Battery Cable Assembly Nut 72 - Drive Motor Battery Cable Terminal Nut 73 - Drive Motor Battery Housing Relay Nut Page 18915 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 1953 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Brakes - Front Brake Induced Pulsation/Vibration Brake Rotor/Disc: All Technical Service Bulletins Brakes - Front Brake Induced Pulsation/Vibration TECHNICAL Bulletin No.: 10-05-23-001B Date: April 13, 2011 Subject: Brake Induced Pulsation/Vibration Felt in Steering Wheel, Rumble Noise from Underbody During Downhill Descent (Verify Condition and Replace Front Brake Pads) Models: 2008 Chevrolet Silverado Light Duty (LD) 2008 GMC Sierra Light Duty (LD) 2nd-Design Only - w/ Pad Spreading Spring Clips (Refer to PIT4611 for Design Identification) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) 2009-2012 Chevrolet Silverado Light Duty (LD) 2009-2012 GMC Sierra Light Duty (LD) Equipped with Disc/Drum Brakes (RPO JF3) and Stabilitrak (RPO JL4) or (RPO JF7) and Stabilitrak (RPO JL4) Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 10-05-23-00A (Section 05 - Brakes). Condition Some customers may comment on a pulsation or vibration mostly concentrated in the steering wheel during downhill descent as specifically described. This condition will most often begin as an increasing rumbling noise coming from the underbody or the front of the vehicle. This condition is exhibited mostly in mountainous regions. Note Use care to ensure the following diagnosis and repair are only attempted if the conditions and concern match those listed, and if the concern can be duplicated under the same conditions. This condition occurs ONLY under the following conditions: - When the vehicle is driven as follows: - On a downhill descent on a fairly steep grade (approximately 5% or greater). - On taller hills (roughly 1.5‹›km [1‹›mi] road length or greater), without sharp turns. - At speeds above 64‹›km/h (40‹›mph). - Using the brakes just enough to maintain the speed limit when moving downhill. - Typically, a rumbling noise will be heard first, building in intensity, followed by increasing pulsation, or vibration, felt in the steering wheel, then typically felt in the floor panel. - The condition will be eliminated once the vehicle is driven on relatively flat ground, typically for 1.5-3‹›km (1-2 mi). Cause This condition may be caused by interaction between the front brake lining material and the front brake rotors. Correction Important DO NOT attempt any repairs on the vehicle until you verify the specific condition is present by following the steps below: 1. Warm up the vehicle by driving approximately 8 km (5 mi). 2. Drive the vehicle in the lane closest to the side of the fairly steep grade (roughly 5 percent or greater), taller hill (roughly 1.5 km [1‹›mi] road length or greater), without sharp turns, and with a speed limit of 64 km/h (40 mph) or greater, with the side windows down. 3. While in Drive, descending downhill, apply the brakes naturally, only as needed, to maintain the speed limit. 4. Observe for noise, followed by pulsation/vibration. Observe where the noise, pulsation and/or vibration are most noticeable. 5. Drive the vehicle on relatively flat ground for 1.5-3 km (1-2 mi) to verify that the condition goes away completely. Note Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Actuator: Locations Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) Front Drive Axle Disassembled Views (8.25 Inch (4WD/Front)) 1 - Output Shaft 2 - Pinion Bearing Spacer 3 - Pinion Head Bearing Assembly 4 - Pinion Shim 5 Stem Pinion 6 - Pinion Flange Nut 7 - Pinion Flange Washer 8 - Pinion Flange Assembly 9 - Pinion Seal 10 - Pinion Tail Bearing Assembly 11 - Carrier Housing 12 - Output Shaft Seal Assembly 13 Output Shaft 14 - Drain Plug Assembly 15 - Drain Plug Washer 16 - Fill Plug Assembly 17 - Fill Plug O-ring Seal 18 - Carrier Locator Pin 19 - Vent Connector 20 - Differential Case 21 - Ring Gear 22 - Output Shaft Bearing Assembly 23 - 8-Point Lock Ring 24 - Sleeve and Insert Assembly 25 Differential Side Bearing Assembly 26 - Differential Cross Pin Lock Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 14322 Locations Knock Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 10205 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Page 13252 Page 15427 Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 3929 Intake Manifold: Service and Repair Upper Intake Manifold Sight Shield Replacement Upper Intake Manifold Sight Shield Replacement Removal Procedure 1. Open the hood. 2. Grasp the front of the intake manifold sight shield and lift up disengaging the grommets from the studs. 3. Remove the intake manifold sight shield from the retainer slots. 4. Remove the intake manifold sight shield retainer bolts and retainer, if required. Installation Procedure Page 8511 Page 8641 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Early Production with HP2) Automatic Transmission Auxiliary Fluid Pump Control Module X1 (Late Production with HP2) Page 15412 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 10296 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. Page 8564 7. Remove the range selector lever nut (1). 8. Remove the range selector lever (2). Installation Procedure 1. Install the range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the range selector lever nut (1). Tighten the nut to 25 Nm (18 lb ft). Page 7903 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 8479 Page 5742 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15682 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 19080 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Page 6094 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 14218 Idler Arm: Service and Repair Idler Arm Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure Caution: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement) . Note Discard the idler arm nut. 2. Remove the idler arm nut (3) from the idler arm (1). 3. Separate the idler arm (1) from the relay rod (2). 4. Remove the idler arm from the relay rod using pullerJ 24319-B . Page 5612 Engine Control Module (ECM) X3 (HP2) Page 15616 Seat Occupant Sensor: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) Specifications Fluid Pan: Specifications Pan Bolts ............................................................................................................................................. .......................................... 30 - 40 Nm (22 - 30 lb ft) Page 19052 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 19303 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8769 Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Special Tools Page 10806 Page 7044 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 5888 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 1187 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (except AN3/DL3) Page 9768 Page 11676 View of the connector when released from the component. View of another type of Micro 64 connector. Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See DIC Warnings and Messages. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. Your dealer/retailer has trained service people who will perform this work using genuine parts and reset the system. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message coming on, reset the system. Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the Engine Oil Life System: 1. Display the OIL LIFE REMAINING on the DIC. If the vehicle does not have DIC buttons, the vehicle must be in P (Park) to access this display. 2. Press and hold the SET/RESET button on the DIC, or the trip odometer reset stem if the vehicle does not have DIC buttons, for more than five seconds. The oil life will change to 100%. If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the Engine Oil Life System has not reset. Repeat the procedure. GM Oil Life System Resetting (From Service Manual) When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System (From Service Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the Page 5741 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11810 Switch Position Icons Page 10316 Page 8148 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 2114 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 9279 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Page 10941 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Note * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement) . * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 1. Remove the J-45101-100 - washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 - washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remainingJ-45101-100 - washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J-39544-KIT - set , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement) . 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer toBrake Rotor Assembled Lateral Runout Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 12662 X305 Body Harness to Passenger Seat Harness (Except AN3/MEX) X309 Diagrams Power Seat Control Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 16030 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor -Passenger (AN3) 4 - Seat Adjuster Switch -Passenger (AG2) 5 - Seat Lumbar Switch -Passenger (AN3) 6 - Seat Belt Buckle -Passenger (10 Series) 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly -Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor -Passenger (AN3) 11 - Seat Lumbar Horizontal Motor -Passenger (AN3) Passenger Seat Components - 2 of 2 Page 7361 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Service and Repair Shift Linkage: Service and Repair Transfer Case Control Rod Replacement Removal Procedure Note Before beginning the following service procedure, place the transmission into the PARK position. Then place the transfer case in the 2 HI position. 1. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement) . 2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . Note When performing this service procedure, use a small pocket screwdriver in order to release the retaining clip on the ends of the control rod. 3. Remove the control rod from the control lever. 4. Remove the control rod from the shift lever. 5. Remove the control rod. Installation Procedure Note * Before installing a NEW control rod, loosen the adjusting bolt on the control rod so it slides with slight resistance. * When installing the control rod on the control levers, a snapping sound should be heard or felt upon installation. Page 16441 Television / Monitor: Service and Repair Video Display Replacement (Second Row) Page 2168 1 - Door Frame 2 - Window Switch -Left Rear (A31) 3 - Window Motor -Left Rear (A31) 4 - Speaker -Left Rear 5 - Inflatable Restraint Side Impact Sensor (SIS) -Left Rear (ASF) 6 - Door Latch -Left Rear Right Rear Door Components (Extended Cab) Page 7716 Switches and Relays Page 13265 Page 2855 Junction Block - Right I/P X4 Page 11675 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Locations Crankshaft Position Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Page 19537 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 13508 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Page 4108 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Front of Vehicle Components (10 Series) Page 8025 Page 3621 Note If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. 12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 13. Disconnect the CH-48027-3 (4) from the fuel rail service port. 14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 15. Install the fuel rail service port cap. 16. Install the engine cover, if required. 17. Tighten the fuel fill cap. Page 14555 7. Install the J 36202 to the adjustment arm and the crossmember. 8. Using the J 36202 , increase the tension on the adjustment arm to load the torsion bar. 9. Turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the crossmember. 11. Remove the safety stands and lower the vehicle. 12. Measure the Z height. Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection) . Page 7572 Input Speed Sensor (ISS) (M30) Page 8227 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics)Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Push To Seat) ( See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (Micro .64) (See: Testing and Inspection/Component Tests and General Diagnostics)Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics)Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics)Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) Connector Anatomy Page 14775 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 3908 34. Install the engine harness clip (4) to the ignition coil bracket stud. 35. Connect the engine harness electrical connectors (3) to the left side fuel injectors. 36. Connect the engine harness electrical connector (2) to the ignition coil harness electrical connector. 37. Install the CPA retainer (1). 38. Connect the engine wiring harness electrical connector (3) to the MAP sensor. 39. Connect the engine harness electrical connector (2) to the EVAP canister purge solenoid. 40. Install the engine harness retainer to the stud and locator pin. 41. Install the engine harness retainer nut (1). Tighten the nut to 5 Nm (44 lb in). 42. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 43. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Service and Repair)Battery Negative Cable Disconnection and Connection (With Dual Batteries) ( Page 18456 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Page 8999 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 12991 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8276 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Instruments - Bulb Outage Detection Restoration Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 2147 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF/NQH) Transfer Case Shift Control Switch (NQG) Page 20209 Page 1694 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Page 12864 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 1284 11 - Inflatable Restraint Seat Position Sensor -Driver (10 Series except MEX) 12 - Seat Adjuster Motor Assembly -Driver (AG1) 13 - Seat Belt Buckle -Driver Driver Seat Components - 2 of 2 1 - Heated Seat Element -Driver Back (AN3) 2 - Heated Seat Element -Driver Cushion (AN3) Door Component Views Page 4980 Air Flow Meter/Sensor: Locations Right Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Right Rear of the Engine Compartment Components (4.8L/5.3L/6.0L/6.2L except HP2) 1 - Battery - Right 2 - A/C Low Pressure Switch (C67/CJ2) 3 - A/C Compressor Clutch (C67/CJ2) 4 - A/C Refrigerant Pressure Sensor (C67/CJ2) 5 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Right Rear of the Engine Compartment Components (HP2) Page 20425 Module Circuit Function Icons Page 13276 Page 3820 Disclaimer MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Page 7930 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 13726 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 20678 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important 09-01-39-004A - END OF INFORMATION NEED Control Module HVAC: Technical Service Bulletins 09-01-39-004A - END OF INFORMATION NEED ENGINEERING INFORMATION Bulletin No.: 09-01-39-004A Date: October 29, 2009 Subject: EI09086 - Automatic HVAC Inoperative, Automatic HVAC Control Replacement or Reprogramming (Engineering Information Closed) Models: 2009 Buick Enclave 2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon, Yukon XL 2009 Saturn OUTLOOK All Equipped with Automatic HVAC (RPO CJ2) Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 09-01-39-004 (Section 01 - HVAC). Additional information is no longer needed by Engineering. Refer to the published diagnostics and repairs in SI to correct this concern. Disclaimer Page 14945 1 - Dome/Reading Lamps - Rear 2 - Electronic Compass Module (YE9) 3 - Inside Air Temperature Sensor (CJ2) Top of the Headliner Components (Crew Cab) Page 3660 Disclaimer Page 11913 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 8133 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 15416 1 - Accessory DC Power Control Module 2 - Drive Motor Generator Power Inverter Module 3 Drive Motor Generator Power Inverter Module Cover 4 - Electronic Power Steering Motor Control Module 5 - A/C Refrigerrant Pressure Sensor 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Front of Vehicle Components (10 Series) Page 20206 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 17499 Door Latch - Left Rear (Crew Cab) Body - Incorrect Sun Visor Label Child Seat: All Technical Service Bulletins Body - Incorrect Sun Visor Label SERVICE UPDATE Bulletin No.: 09146 Date: June 23, 2009 Subject: 09146 - Service Update for Inventory and Customer Vehicles - Incorrect Sun Visor Label Expires with Base Warranty Models: 2009 Chevrolet Silverado 2009 GMC Sierra Export Vehicles THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN TO THE DEALERSHIP FOR ANY REASON. IT WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to install a new sun visor label on certain 2009 Chevrolet Silverado and GMC Sierra export vehicles. These vehicles have an incorrect sun visor label that instructs the driver that a rear-facing child seat should never be put in the front seat. The correct label instructs the driver that the air bag must be turned off when a rear-facing child seat is in the front seat. Vehicles Involved Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved. Parts Information Labels required to complete this update are being provided to dealers at no charge. Service Procedure 1. Ensure that the existing label on the driver's sun visor is clean and dry. 2. Remove the backing from the new label. 3. Apply the new label over the existing label and smooth the label from the center out. 4. Repeat on the passenger's sun visor Claim Information For vehicles repaired under this service update, use the table above. Page 13419 view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if The Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Testing for Continuity Testing for Continuity Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the Ω position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Page 11534 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 13942 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 6815 Tighten the clamp to 2.5 Nm (22 lb in). 5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 7. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 Nm (80 lb in). 8. Lower the vehicle. 9. Install the fuel tank filler housing. 10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 Nm (20 lb in). 11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 Gal Tank) Page 16267 1 - Drive Motor Battery High Voltage Manual Disconnect Lever 2 - Rear Seat - Folded 3 - Drive Motor Generator Battery (HP2) Page 9835 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5580 For vehicles repaired under warranty, use the table above. Disclaimer Page 3106 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 15 Nm (11 lb ft). Page 14255 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Steering/Suspension - Power Steering Fluid Leaking Power Steering Pump: Customer Interest Steering/Suspension - Power Steering Fluid Leaking ENGINEERING INFORMATION Bulletin No.: 07-02-32-002J Date: July 23, 2010 Subject: EI07082 - Power Steering Fluid Leaking from Power Steering Gear/Rack Assembly (Engineering Recommendations / Engineering Information Closed) Models: 2008-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 GMC Denali, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series Only and Excluding Hybrids Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-02-32-002I (Section 02 - Steering). Condition Some customers may comment on a fluid leak. Upon investigation, the technician may find fluid leaking from the power steering system. Please use the following information to assist in diagnosis. Diagnostic Information Important All potential leaks should be completely cleaned and identified before attempting to repair or replace any power steering components. 1. Start diagnosis by inspecting the fluid level in the power steering reservoir. If the fluid level is NOT low, a careful analysis of the condition is necessary as it may involve a different type of fluid leak. 2. Visually inspect the components where the fluid has accumulated. 3. Completely clean off any fluid residue from the suspect components. 4. Apply tracing powder to the suspect components. This is an effective way to determine the source of a leak. As an alternative, fluorescent dye (such as Kent Moore J 28431-6) may be added to the power steering fluid. 5. Start the vehicle and allow the power steering system to reach normal operating temperatures. 6. Turn the steering wheel to the stops in each direction while bumping the steering wheel against the stops 3-4 times. This will build maximum steering system pressure and help identify the source of the leak if present. 7. Determine the source of the leak. 8. If a repeatable leak is found, refer to the following tables to determine the proper corrective action needed. Repairable Leaks Non- Repairable Leaks *If fluid is observed at the adjuster plug during the initial visual inspection, then refer to the following: - Seepage at the adjuster plug may not necessarily indicate an active leak. Power steering fluid is used during the manufacturing of the gear/rack. The fluid used at assembly is pushed into the pinion area during assembly. The adjuster plug and the area below the pinion are not positively Page 8760 * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics) Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) . Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) . Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6042 Page 11098 12. Connect the right rear brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . 13. Connect the left rear brake pipe fitting (2) and tighten to 18 Nm (13 lb ft) . 14. Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting. Page 13631 Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 14318 Steering Control Module: Diagrams Component Connector End Views Electronic Power Steering Motor Control Module X1 (HP2) Electronic Power Steering Motor Control Module X3 (HP2) Page 15351 1 - I/P Trim 2 - Junction Block - Right I/P Below the Left Side of the I/P Components - 1 of 2 Page 1601 1 - Inside Air Temperature Sensor (CJ2) 2 - Cellular Telephone Microphone (UE1/U3U/UVB) 3 Dome/Reading Lamps -Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade -Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly (UE1) 8 - Inside Rearview Mirror (ISRVM) 9 - Dome/Reading Lamps -Front 10 - Windshield 11 - Sunshade -Left (DH6) Overhead Console Components Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Page 9029 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing Page 7200 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 7369 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9235 Caution: Bolt torque sequencing is critical to the proper function of the control solenoid valve assembly. Failure to follow the required sequencing may result in transmission malfunction. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Torque the control valve channel plate bolts following the specified sequence. Tighten the bolts to 11 Nm (97 lb in). Caution: Bolt torque sequencing is critical to the proper function of the control solenoid valve assembly. Failure to follow the required sequencing may result in transmission malfunction. 8. Torque the control valve body bolts following the specified sequence. Tighten the bolts to 11 Nm (97 lb in). Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5341 4. Remove the accelerator pedal. Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the accelerator pedal bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Page 1735 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: Important: Close the hood. Important: The engine must be at operating temperature. 1. Block drive wheels. 2. Set parking brake. 3. Apply and hold brake pedal. Important: The engine may autostop and will restart as needed. Important: The vehicle must remain in PARK. 4. Start the engine. Important: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP System Variation Learn Procedure with a scan tool. 6. Quickly apply and release the accelerator pedal. Important: The engine may autostop and will restart as needed. 7. Test in progress. Important: If the scan tool indicates that DTC P0315 ran and passed, the CKP Variation Learn Procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer toDTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315) . If any other DTCs set, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) for the applicable DTC that set. 8. The scan tool displays Learn Status: Learned this ignition. 9. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 10. The CKP Variation Learn Procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Drivetrain - Excessive Effort When Shift 2HI to 4HI Case: Customer Interest Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 738 Page 17987 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 9090 Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7026 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Page 7218 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Page 11363 Page 2651 Fuse Block - Underhood X7 (Chassis Harness) Fuse Block - Underhood X7 (Auxiliary Battery Positive Cable) (TP2) Fuse Block - Underhood X8 (Instrument Panel Harness) Page 11561 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Page 7813 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Page 15067 Page 5415 Auxiliary Body Control Module (XBCM) X2 (EXP) Page 12644 X215 Inline Harness Connector End Views X215 Body Harness to I/P Harness (HP2) Page 16172 Page 7978 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. Page 7725 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics) Page 18699 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools J 8001 Dial Indicator Set Note This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Turn the ignition key to the on position with the engine off. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold it in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 4. If there is not a good location for the dial indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the dial indicator pointer. 5. Install a dial indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Page 15162 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Page 13178 Fuse Block - Auxiliary X3 (HP2) Page 5940 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1560 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67/C42/MEX) Ambient Light/Sunload Sensor (CJ2) Page 8772 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4546 4. Remove the drive motor generator power inverter control module (PIM) cover fasteners (1). 5. Remove the PIM cover (2). Discard the cover seal (3). Caution: Always remove and install the High Voltage terminal fasteners with a magnet tipped socket. Never touch the exposed electronic circuit board surface or components. Dropped fasteners or physical contact may result in electronic circuit board damage. 6. Remove the HV dc accessory DC power control module (APM) terminal fasteners (1) utilizing a magnetic socket. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: All Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 13860 X303 Body Harness to Driver Seat Harness (Except AN3/MEX) X303 Driver Seat Harness to Body Harness (MEX/A52) Page 15971 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Page 10784 2. Turn the ignition key to the "OFF" position, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 3. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 4. Without the brake pedal applied, turn the ignition key to the "ON" position, with the engine OFF. 5. Using the Tech 2(R) scan tool, check the brake pedal travel using the steps below: 1. Select Diagnostics. 2. Build the appropriate vehicle information. 3. Select Chassis. 4. Select if the vehicle is equipped with Magnetic Ride Control Suspension Package (RPO Z95). 5. Select Electronic Brake Control Module (EBCM). 6. Select Data Display. 7. Under the Data List, scroll down the list and select "BMC Primary Piston Ref. Position" and "Master Cylinder Pressure Sensor" items as shown: Note First highlight the line and press the "Enter" soft key on the Tech 2(R) to get the "*" as shown for each item. - BMC Primary Piston Ref. Position - Master Cylinder Pressure Sensor - Then "Accept" the two selected items as shown on the top of the Tech 2(R) scan tool. 6. While observing the Master Cylinder Pressure Sensor on the scan tool data display, using moderate speed and moderate effort, depress the brake pedal to a force of 5,000 kPa (725 psi). 7. Record the distance displayed on the scan tool that the BMC Primary Piston has travelled at the applied brake pedal force of 5,000 kPa (725 psi). 8. Release the brake pedal. 9. Wait 15 seconds, then repeat steps 6-8 to obtain a second measurement. Page 17121 4. Tighten the trailer brake control module bolts (1) to 9 Nm (80 lb in) . 5. Connect the trailer brake control module electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . 7. If installing a new trailer brake control module, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 8877 Page 18825 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 2247 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications) . When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment) . Page 369 Seat Climate Control Module X1 (KB6) Page 7836 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. Page 8018 23 - Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear 24 - Transfer Case Front Output Shaft Drive Sprocket Retaining Ring 25 - Transfer Case Oil Pump Assembly 26 - Transfer Case Rear Output Shaft Speed Reluctor Wheel 27 - Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 28 - Transfer Case Rear Output Shaft Rear Bearing Assembly 29 Transfer Case Rear Output Shaft Rear Bearing Retaining Ring 30 - Transfer Case Oil Pump Suction Pipe Seal 31 - Transfer Case Oil Pump Suction Pipe 32 - Transfer Case Front Output Shaft Rear Bearing Assembly 33 - Transfer Case Front Output Shaft Driven Sprocket Spacer 34 Transfer Case Front Output Shaft Driven Sprocket 35 - Transfer Case Front Output Shaft Hole Plug 36 - Transfer Case Front Output Shaft 37 - Transfer Case Front Output Shaft Front Bearing Assembly Clutch Components Page 12239 Junction Block - Left I/P X12 (except MEX) Page 11030 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) . Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning) . Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) . 2. Drain all the brake fluid from the caliper. Note The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 10760 Front Axle (NP8) 1 - Frame 2 - X110 (NQF/NQG/NQH/NP2) 3 - Front Axle Housing 4 - Front Drive Axle Actuator (NQF/NQG/NQH) Page 189 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17312 For vehicles repaired under warranty, use the table above. Disclaimer Page 4938 Page 16331 * Easy Exit Recall * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy serial data message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via a serial data message. The instrument panel cluster receives a serial data message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting . Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a serial data message with the fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a serial data message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a serial data message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Page 20607 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 12391 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 20230 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: All Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2180 Door Lock/Window Switch - Passenger X1 (AN3/DL3) Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Page 1730 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (4.3L) Crankshaft Position (CKP) Sensor (4.8L/5.3L/6.0L/6.2L) OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 13324 Fuse Block - Underhood X5 Page 3823 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations . 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level by adding or draining oil. 16. Check for oil leaks. 17. Close the hood. Page 1693 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Engine - Oil Consumption On Aluminum Block Engines Oil Pressure Regulator Valve: All Technical Service Bulletins Engine - Oil Consumption On Aluminum Block Engines TECHNICAL Bulletin No.: 10-06-01-008B Date: March 07, 2011 Subject: Engine Oil Consumption on Aluminum Block Engines with Active Fuel Management (AFM) (Install AFM Oil Deflector and Clean Carbon from Cylinder) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado 1500, Suburban, Tahoe 2007-2009 GMC Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2009 Pontiac G8 GT Equipped with Aluminum Block V8 Engine with Active Fuel Management (AFM) (RPOs LC9, LH6, L76, LFA, L92) with Greater than 45,000 km (28,000 mi) Supercede: This bulletin is being revised to add the 2009 model year and new Correction information for the 2009 model year - left rocker arm cover replacement. Information has also been added after step 9. Please discard Corporate Bulletin Number 10-06-01-008A (Section 06 Engine/Propulsion System). Condition Some customers may comment about engine oil consumption of vehicles with higher mileage (approximately 48,000 to 64,000 km (30,000 to 40,000 mi). Verify that the induction system is assembled correctly and that there is no evidence that the engine has been ingesting dirty air due to a mis-assembled induction system. Also verify that the PCV system is functioning properly. If diagnostic procedures indicate that oil consumption is piston /piston ring related, verify that oil consumption is less than 3,000 km (2,000 mi) per liter/quart. If these conditions are met and oil consumption is less than 3,000 km (2,000 mi) per liter/quart, perform the service indicated in this bulletin. Cause This condition may be caused by oil spray that is discharged from the AFM pressure relief valve within the crankcase. Under most driving conditions and drive cycles, the discharged oil does not cause a problem. Under certain drive cycles (extended high engine speed operation), in combination with parts at the high end of their tolerance specification, the oil spray quantity may be more than usual, resulting in excessive deposit formation in the piston ring grooves, causing increased oil consumption. Correction 2009 Vehicles Only Important This left rocker arm cover is NOT to be used on 2007-2008 vehicles because of the calibration of the PCV orifice being different in 2007-2008. A new left rocker arm cover has been released for 2009 engines. Technicians should replace the left rocker arm cover with GM P/N 12642655. This rocker arm cover has relocated PCV drain holes that prevents PCV pullover into the intake manifold. Refer to SI for Valve Rocker Arm Cover Replacement - Left Side. 2008-2007 Vehicles Only To correct this condition, perform the piston cleaning procedure as described in this document, and install a shield over the AFM pressure relief valve per the procedure outlined in this document. Monitor oil consumption after this repair to ensure oil consumption has improved to acceptable levels. If this repair does not correct the condition, it may be necessary to replace the piston assemblies (piston and rings) with new parts. Important It is critical in this cleaning process that the engine/fuel injector cleaner remain in the cylinders for a minimum of 2.5 hours to fully clean the components. The cleaner solution must be removed before a maximum of three hours. 1. Verify the oil consumption concern following Corporate Bulletin Number 01-06-01-011F. If oil consumption is found, continue on with this bulletin. 2. Remove the spark plugs and ensure that none of the pistons are at top dead center (TDC). 3. Clean the pistons by putting 118-147 ml (4-5 oz) of Upper Engine and Fuel Injector Cleaner, GM P/N 88861802 (in Canada, use 88861804), in each cylinder. Allow the material to soak for at least 2.5-3.0 hours, but no more than three hours and then remove the cleaner. A suggested method Page 751 Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement (1500) Voice Recognition System - Won't Recognize Bluetooth(R) Emergency Contact Module: All Technical Service Bulletins Voice Recognition System - Won't Recognize Bluetooth(R) INFORMATION Bulletin No.: 08-08-44-024 Date: June 27, 2008 Subject: Voice Recognition System Will Not Recognize "Bluetooth" Command Models: 2009 Buick Enclave 2009 Cadillac CTS, SRX 2009 Chevrolet Avalanche, Cobalt, Corvette, Equinox, HHR, Silverado, Suburban, Tahoe, Traverse 2009 GMC Acadia, Sierra, Yukon 2009 Pontiac G5, Solstice, Torrent 2009 Saturn OUTLOOK, SKY, VUE with UE1 (OnStar) but Without UPF (Bluetooth) 2009 Cadillac STS with UE1 (OnStar) and YQ4 (Bluetooth in Nav Radio) On vehicles not equipped with Bluetooth, the voice recognition system will not recognize the "Bluetooth" command even though the voice prompts indicate "Bluetooth" is an option. Description Proper Operation In the voice recognition menu (entered through the Steering Wheel Control Switch), the customer says "Bluetooth." If the vehicle is equipped with Bluetooth (all except STS), a "Bluetooth Ready" audio prompt will play. If the vehicle consistently responds with "Pardon" or some other response, then the vehicle does not have the Bluetooth functionality (UPF Option code). The UPF option has to be factory installed in order for the "bluetooth" command to function (all except STS). Typical Customer Experience Enter into the voice recognition menu through the Steering Wheel Control Switch (For vehicle specific instructions on how to enter the voice recognition menu, reference the vehicle owner's guide.) Here is the expected dialogue: ^ System Response: "Ready" ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System response: "Sorry I didn't get that. You can say dial, store, call, Bluetooth, more commands, help, or goodbye". ^ Customer says, "Bluetooth" ^ System Response: "Pardon" ^ Customer says, "Bluetooth" ^ System Response: "Thank you. Goodbye" and the session is ended. Important: When the customer says, "Bluetooth" in a vehicle without the Bluetooth feature, this may also disable the system's ability to respond to the "more help" command. Please instruct customers not to attempt Bluetooth functionality if their vehicle is not equipped with the option. STS Only The STS may experience the same condition as stated above even if the vehicle is equipped with the YQ4 (Bluetooth/Nav Radio) option if the voice recognition mode is entered through the steering wheel control. The STS has the Bluetooth functionality as part of the Navigation Radio, and Bluetooth must be entered from the radio itself. To enter Bluetooth mode on the STS: 1. PRESS the CONFIG hard key on the radio. Page 17373 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 18489 Seat Horizontal Motor - Driver (HP2) Page 8183 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Page 7356 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Page 7364 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Page 7896 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 17787 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 10591 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P (except MEX) 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module (NQF/NQH) 7 - Fuse Block - I/P Page 8223 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Locations Auxiliary Water Pump Relay: Locations Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 6813 Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 2943 and Inspection/Component Tests and General Diagnostics) . 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. Page 12167 Fuse Block - Underhood X6 Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 13032 Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12960 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 1178 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3/AP8) Page 7987 Page 8295 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 430 8. Install the ABS module splash shield retainer (1). Page 19068 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Page 18303 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Initialization/Teach Procedure (Manual Method), New/First Time Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window stall at the front hard stop in the VENT OPEN position, and then moves slightly to the soft stop position. Release the button. (This is the initialization portion). 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion). 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Page 16519 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 8997 Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) . 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5413 Body Control Module (BCM) X7 (Except MEX/A52) Page 6097 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 10196 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 6123 Page 2668 Fuse Block - Auxiliary X3 (HP2) OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 1137 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp - Right 6 - Object Alarm Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Alarm Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Alarm Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Alarm Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left Page 19407 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17164 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 4. Tighten the trailer brake control relay bolts (1) to 6 Nm (53 lb in) . 5. Connect the trailer brake control relay electrical connector. 6. Install the spare tire and wheel assembly. Refer to Spare Wheel Hoist Replacement (See: Maintenance/Wheels and Tires/Tires/Spare Tire/Service and Repair) . Page 16066 Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Page 12230 Page 16546 refer to this letter and the Bulletin No. shown above. We apologize for any inconvenience that this may cause. Please know that your safety and security is our priority. Page 8019 Clutch Components 1 - Transfer Case Rear Output Shaft 2 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 3 - Transfer Case Control Lever 4 - Transfer Case Control Actuator Lever Bearing Assembly 5 - Transfer Case Control Actuator Lever Ball (Qty: 3) 6 - Transfer Case Control Actuator Lever Assembly 7 - Transfer Case Control Actuator Lever Thrust Bearing Assembly 8 - Transfer Case Control Actuator Lever Washer 9 - Transfer Case Four Wheel Drive Clutch Pressure - Apply Plate Page 11273 5. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 6. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling) . 8. Adjust the park brake. Refer to Parking Brake Adjustment (Drum Brake) (See: Adjustments/Parking Brake Adjustment (Drum Brake))Parking Brake Adjustment (Disc Brake) (See: Adjustments/Parking Brake Adjustment (Disc Brake)) . Parking Brake Rear Cable Replacement - Right Side (JF3, JF7) Parking Brake Rear Cable Replacement - Right Side (JF3, JF7) Special Tools J 37043 Park Brake Cable Release Tool Removal Procedure Page 13349 Junction Block - Left I/P X5 (SPO Alarm) Camshaft Timing Chain and Sprocket Replacement Timing Chain: Service and Repair Camshaft Timing Chain and Sprocket Replacement Camshaft Timing Chain and Sprocket Replacement Special Tools * EN 46330 Timing Chain Tensioner Retaining Pin * J 8433 Puller Bar * J 41478 Crankshaft Front Oil Seal Installer * J 41558 Crankshaft Sprocket Remover * J 41665 Crankshaft Balancer and Sprocket Installer * J 41816-2 Crankshaft End Protector * J 42386-A Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (LH6, LMG, LY2 and LY5) (See: Engine Lubrication/Oil Pump/Service and Repair)Oil Pump, Screen, and Crankshaft Oil Deflector Replacement (Except LH6, LMG, LY2 and LY5) ( See: Engine Lubrication/Oil Pump/Service and Repair) . 2. Remove the starter motor. Refer to Starter Replacement (4.8L, 5.3L, 6.0L, and 6.2L) ()Starter Replacement (4.3L) ()Starter Replacement (6.6L) () . Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . Note Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel. 3. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation. Tighten the J 42386-A bolts to 50 Nm (37 lb ft). Page 8866 Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the Drivetrain - Excessive Effort When Shift 2HI to 4HI Differential Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Excessive Effort When Shift 2HI to 4HI TECHNICAL Bulletin No.: 09-04-19-002A Date: February 17, 2011 Subject: 4WD System Shift Performance in Cold Ambient Temperatures (Use Synthetic Fluid in Light Duty Front Axles with 8.5" Ring Gears) Models: 1999-2011 Chevrolet Silverado 1500 Series Models 1999-2011 GMC Sierra 1500 Series Models Equipped with 4WD and 8.25" Front Axle Ring Gears (Transfer Case RPOs NP2, NQG) Attention: It is important to determine the RPO for the transfer case in GWM/IVH prior to applying this bulletin. This bulletin applies ONLY to vehicles equipped with 8.25" front axle ring gears, used in conjunction with a manual transfer case (RPOs NP2, NQG). Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-04-19-002 (Section 04 - Driveline/Axle). Condition Some customers may comment about the effort required to shift from 2HI to 4HI in cold ambient temperatures at -6°C (20°F) or below. Cause This condition may be caused by the standard front axle being equipped with conventional mineral oil axle fluid. In cold ambient temperatures, prior to complete warm up, the fluid viscosity is thick. This may affect transfer case shift performance prior to full warm up. Correction Drain the front axle fluid and refill with GM SAE 75W-90 Synthetic Axle Fluid, P/N 89021677 (in Canada, 89021678). Refer to Front Axle Lubricant Replacement in SI. It is important to use synthetic fluid in this 8.25" axle to improve the performance of the 4WD system in cold ambient temperatures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 19696 1 - Fuel Level Sensor -Secondary (31 Series without NQZ) 2 - Fuel Pump (31 Series without NQZ) 3 - Fuel Level Sensor -Primary Page 20921 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 13937 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 17535 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 428 1. Position the EBCM (1) to the BPMV. 2. Push the EBCM squarely onto the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 3. Install the EBCM bolts (1) and tighten in a cross pattern to 3 Nm (27 lb in) . 4. Connect the EBCM electrical connector. 5. If installing a new EBCM, the EBCM must be programmed and the sensor and boost valve calibration and EBCM learn processes must be performed. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 12310 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 8864 Note A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) for the appropriate connector repair procedure. GMLAN Wire Repair Note Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 107 Submit a Product Claim with the information above. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information above. Page 6821 Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 17040 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Page 9756 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 13870 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 18248 For vehicles repaired under warranty, use the table. Disclaimer Page 1261 1 - Heated Seat Element -Passenger Back (AN3) 2 - Heated Seat Element -Passenger Cushion (AN3) Passenger Compartment/Roof Component Views Driver Seat Components - 1 of 2 Page 13835 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Page 7315 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Instruments - Compass/Temperature Display Information Compass: Technical Service Bulletins Instruments - Compass/Temperature Display Information INFORMATION Bulletin No.: 07-08-48-004A Date: June 13, 2008 Subject: Information on Outside Temperature and Compass Displays on Inside Rearview Mirror Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 with RPO DF5 or TQ5 (Intellibeam(R)) Inside Rearview Mirror Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 07-08-48-004 (Section 08 - Body and Accessories). Some dealers/customers may notice that the outside temperature and compass are not displayed in the inside rearview mirror. The mirrors are usually turned on when the vehicles leave the assembly plant, but there may be situations when the mirrors may be turned off by the transport company, dealer personnel and/or the customer. If you experience a vehicle that has an inoperative compass and temperature display, make sure that the function is turned on in the mirror. Briefly press the on/off button on the left side of the mirror (RPO DF5) to turn the display on. The green LED that is on the left side of the mirror is for the automatic dimming function. There has been some confusion in which a customer sees the green LED and thinks that this automatically means the compass and the temperature display should be illuminated. So the customer may not try to turn the function on. If the vehicle is equipped with the Intellibeam(R) (RPO TQ5) mirror, press and hold the auto headlamp button on the left side of the mirror for 3-5 seconds. The Warranty Parts Center (WPC) has found that several of the mirrors were returned with the function turned off and there were no problems found with the mirror. Disclaimer Page 1765 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab With 26 gal Tank) Fuel Tank Pressure Sensor Replacement (15 Ext/Crew Cab w/26 gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (15 Rec Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair)Fuel Tank Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Page 3023 Page 5193 * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Refer to Knee Bolster Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair)Knee Bolster Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair) . Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Page 11404 Page 744 Engine Control Module (ECM) X2 (5.3L/L76 or 6.2L Except Y91) Page 20596 Door Lock/Window Switch - Passenger X7 (AN3/DL3) Page 11777 Ignition Switch Lock Cylinder: Removal and Replacement Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning) . 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement) . 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair) . 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 13534 Fuse Block: Connector Views Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 6758 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 11642 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ω). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9371 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the fill plug (1). 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Page 6441 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 9508 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair/Wheel Drive Shaft Replacement)Wheel Drive Shaft Replacement (1500) (See: Service and Repair/Wheel Drive Shaft Replacement) . 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair/Front Wheel Drive Shaft Seal Protector Replacement) . Note Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Page 12305 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics) . * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics) . Page 14888 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Blunt Cut - Mobile Radio Provision 11 - X226 12 - Instrument Panel Behind the I/P Components (EXP) Page 9686 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 11179 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 12734 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Page 6648 Page 13775 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 8793 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4077 5. Install the spark plug wire to the spark plug. 6. Inspect the spark plug wire for proper installation: 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 7. If a right side spark plug(s) was replaced, install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 8. If a right side spark plug(s) was replaced, perform the service reconnect. Refer to High Voltage Enabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . Page 17837 Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Page 6642 Fuel Injector 4 (Diesel) Page 11110 14. Tighten the brake modulator manual pressure relief valve (1) to 40 Nm (30 lb ft) . 15. Perform the Antilock Brake System Automated Bleed Procedure (See: Brake Bleeding) . Follow the procedure completely to ensure the learn procedure for the pressure and travel sensors has occurred. Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set Control Module: All Technical Service Bulletins Drivetrain - 4 Wheel Drive Message/DTC C0387/C0569 Set TECHNICAL Bulletin No.: 09-04-21-001 Date: May 19, 2009 Subject: Service 4 Wheel Drive Message - DTC C0387 C0569 Set (Reprogram Transfer Case Control Module) Models: 2009 Cadillac Escalade Hybrid 2007-2009 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2007-2009 GMC Sierra, Sierra Hybrid, Yukon, Yukon Hybrid, Yukon XL All Equipped with Transfer Case RPO NQF or NQH Condition Some customers may comment that the Service 4 Wheel Drive message is displayed. This may be the result of setting DTC C0387 or DTCs C0387 and C0569. When the code is current, the transfer case system remains inoperative for the rest of the ignition key cycle. For RPO NQF vehicles, both C0387 and C0569 may be set together with or without requesting a transfer case shift. For RPO NQH vehicles, the C0387 may be set when requesting a transfer case mode or range shift. On RPO NQH transfer cases, these DTCs can also be set during normal driving conditions in Auto 4WD, 4HI or 4LO. These DTCs may intermittently set during extreme cold or warm weather, or periods of lower than normal battery charge. Cause The Service 4 Wheel Drive message and the resulting DTC(s) set is a result of the Transfer Case Control Module (TCCM) software not updated to the latest version. Correction Important DO NOT replace the TCCM for this condition. Reprogram the TCCM with the revised calibration and then perform the Clutch Reset Procedure (Motor Learn Procedure). Important If DTC C0387 or DTCs C0387 and/or C0569 occur, check connectors and wiring, and service as necessary prior to reprogramming the TCCM. 1. Reprogram the TCCM with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the TCCM using the Service Programming System (SPS) with the latest software available on TIS2WEB. Refer to Transfer Case Shift Control Module Programming and Setup procedures in SI. As always, make sure your Tech 2(R) is updated with the latest software version. Important A voltage of 10.5 or higher is required to successfully complete the Clutch Reset Procedure without setting DTCs. 2. Perform the Clutch Reset Procedure (Motor Learn Procedure). Refer to Transfer Case High/Low Clutch Reset in SI. 3. Read and clear all the DTCs. 4. Perform the following mode and range shifts: 2HI - 4HI, 2HI - 4LO, 2HI - Neutral. 5. Test drive the vehicle. Use all modes, including 'Auto' mode for RPO NQH vehicles. Warranty Information For vehicles repaired under warranty, use the table above. Page 13839 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (HP2/Late Production except Y91/MEX/8S8) Page 12526 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 18850 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Page 16034 Seat Occupant Sensor: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 19577 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 12273 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the Left Side of the I/P Components - 2 of 2 Page 8233 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9031 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) . 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gage size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) . Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics) . 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Page 8190 Module Circuit Function Icons Page 10927 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 13707 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Page 12353 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1406 1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ECT sensor. Tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the ECT sensor (1). 4. Refill the cooling. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair) . Page 10984 5. Install the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to install to the hold down pins. 6. Disassemble, clean and lubricate the threads of the brake shoe adjuster with high temperature brake lubricant. 7. Assemble the brake shoe adjuster. 8. Spread the brake shoes apart slightly and install the brake shoe adjuster (1). Page 5801 High Speed Bus - 6 of 6 (HP2) Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Wheels/Tires - Module Programming For 20/22 Inch Wheels PROM - Programmable Read Only Memory: Customer Interest Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 18844 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note The TPA is fragile and may break if not done carefully. Page 8149 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Page 2205 Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 19769 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 418 Electronic Brake Control Module (EBCM) (JH6/JH7) Page 7605 1 - Transfer Case Encoder Motor 2 - Vehicle Speed Sensor (VSS) 3 - Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 14642 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 2979 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Page 6232 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Engine Coolant Temperature (ECT) Sensor 4 - Camshaft Position (CMP) Sensor 5 - A/C Compressor Rear of the Engine Components (LFA/HP2) Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Front Seat Center Belt Replacement Seat Belt: Service and Repair Front Seat Center Belt Replacement Front Seat Center Belt Replacement Page 18001 Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3/AP8) Page 11579 Negative: Service and Repair Engine Ground Strap Replacement Engine Ground Strap Replacement Removal Procedure 1. Remove the engine wiring harness ground bolt. 2. Reposition the engine wiring harness ground and ground strap. 3. Remove the ground strap nut from the stud at the front of dash. 4. Remove the ground strap from the stud. Installation Procedure 1. Install the ground strap to the stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the ground strap nut to the stud at the front of dash and tighten to 9 Nm (80 lb in) . 3. Position the ground strap and engine wiring harness ground. 4. Install the engine wiring harness ground bolt and tighten to 16 Nm (12 lb ft) . Page 13522 circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3066 Junction Block - Rear Lamps X4 Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Glove Compartment: Service and Repair Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Page 7339 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair)Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Page 20846 Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Page 2980 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Page 18328 Note Transfer the air deflector parts to the new air deflector. 1. Position the sunroof air deflector (2) to the sunroof module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 2. Install the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). Tighten the screws to 2 Nm (18 lb in). 3. Install the actuators screws (1) and actuators (2) to each side sunroof module. Tighten the screws to 2 Nm (18 lb in). 4. Verify that the spring action of the sunroof air deflector is operating. 5. Close the sunroof window. Page 17329 1 - Outside Rearview Mirror -Passenger 2 - Door Lock Switch -Passenger 3 - Door Lock/Window Switch -Passenger 4 - Door Latch -Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) -Right Front (ASF) 6 - Speaker -Right Front 7 - Window Motor -Passenger (A31) 8 - Window Switch -Passenger (A31) 9 - Heated Seat Switch -Passenger (AN3) Driver Door Components (except AN3/DL3) Page 811 15. If all circuits test normal, replace the relay. Repair Instructions * Engine Control Module Programming and Setup (Gasoline Engines) (See: Testing and Inspection/Programming and Relearning)Engine Control Module Programming and Setup (W/RPO LMM) (See: Testing and Inspection/Programming and Relearning) * Engine Control Module Replacement (See: Relays and Modules - Computers and Control Systems/Engine Control Module/Service and Repair) * Relay Replacement (Attached to Wire Harness) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Attached to Wire Harness))Relay Replacement (Within an Electrical Center) (See: Relays and Modules - Power and Ground Distribution/Power Distribution Relay/Service and Repair/Relay Replacement (Within an Electrical Center)) Repair Verification 1. Install any components that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming, or setup procedures that are required when a component or module is removed or replaced. 3. Clear the DTCs. 4. Turn OFF the ignition for 60 seconds. 5. Ignition ON, command the powertrain relay ON and OFF with a scan tool, while observing the powertrain relay circuit status parameters, The circuit status parameters should change from OK to Not Run or Not Run to OK. ‹› If another DTC is present, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions) and perform the appropriate diagnostic procedure. Page 14798 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 4494 Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Body - Roof Panel Flutters/Rattle Noise When Doors Close Headliner: All Technical Service Bulletins Body - Roof Panel Flutters/Rattle Noise When Doors Close TECHNICAL Bulletin No.: 08-08-67-016F Date: January 24, 2011 Subject: Roof Panel Flutters or Rattle Noise from Roof or Headliner when Closing Doors (Apply Foam) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Models Only), Suburban, Tahoe 2010-2011 Chevrolet Equinox 2007-2009 GMC Sierra (Crew Cab Models Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2010-2011 GMC Terrain Supercede: This bulletin is being revised to add the 2011 model year to Equinox/Terrain models. Please discard Corporate Bulletin Number 08-08-67-016E (Section 08 - Body and Accessories). Condition Some customers may comment that the roof panel flutters and/or there is a rattle noise from the roof or headliner when closing one of the side doors or the liftgate. Cause This may be caused by the excessive motion of the roof panel. On initial inspection, you may notice that the roof panel expansion adhesive material has separated between the roof and the roof bow. The concern is seen mostly on the first cross bow. Correction Lower the headliner assembly (it is not usually necessary to remove the headliner from the vehicle) to gain access to the roof bows. Refer to Headlining Trim Panel Replacement in SI. Remove any loose foam from the roof bow or bows. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or equivalent, in a continuous bead the entire length between the roof bow reinforcement and the roof outer panel. Reinstall the headliner. Refer to Headlining Trim Panel Replacement in SI. Parts Information Contact Lord Fusor at 1-877-275-5673 or on the Web at www.lord.com. Warranty Information For vehicles repaired under warranty, use the table. Page 12696 X113 Engine Jumper Harness to Engine Harness (Diesel) Page 8809 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 6891 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform theDiagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * ReviewStrategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test) . Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 35616 GM-Approved Terminal Test Kit * J 43244 Relay Puller Pliers Circuit/System Verification 1. Ignition OFF, open the hood to disable the Auto-Stop function. Refer to Hybrid Modes of Operation Description (See: Hybrid Drive Systems/Description and Operation/Hybrid Controls/Hybrid Modes of Operation Description) . 2. Ignition ON, verify the scan tool hood position parameter displays Open. ‹› If the hood position does not display Open, refer toDiagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Page 8824 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10744 12. Connect the right rear brake pipe fitting (1) and tighten to 18 Nm (13 lb ft) . 13. Connect the left rear brake pipe fitting (2) and tighten to 18 Nm (13 lb ft) . 14. Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting. Page 1831 2. Install the HO2S (4). Tighten the sensor to 42 Nm (31 lb ft). 3. If equipped with 4WD perform the following steps, if equipped with 2WD proceed to step 6. 4. Connect the HO2S electrical connector (4) to the engine wiring harness electrical connector (3). 5. Install the CPA retainer (2). 6. Connect the HO2S electrical connector (3) to the engine wiring harness electrical connector (5). 7. Install the CPA retainer (2). 8. Lower the vehicle. Page 10261 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Page 1898 1 - Valve Lifter Oil Manifold (VLOM) Assembly 2 - Fuel Injector 8 3 - Fuel Injector 6 4 - Fuel Injector 4 5 - Fuel Injector 2 6 - Ignition Coil 2 7 - Ignition Coil 4 8 - Ignition Coil 6 9 - Knock Sensor (KS) 2 10 - Ignition Coil 8 11 - Crankshaft Position (CKP) Sensor Front of the Engine Components (LFA/HP2) Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Fuel Tank Pressure Sensor Replacement Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Refer to Fuel Tank Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair) . Page 10123 Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 1. Install the speed sensor with a NEW O-ring. Page 7741 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7798 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 8314 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts - First Pass...................................................................................................... ..........................................................15 Nm (11 lb ft) Exhaust Manifold Bolts - Final Pass................. ..............................................................................................................................................20 Nm (15 lb ft) Exhaust Manifold Heat Shield Bolts....................................................................................... .........................................................................9 Nm (80 lb in) Exhaust Manifold Studs...................... ............................................................................................................................................................2 0 Nm (15 lb ft) Engine - MIL ON P0116/P1400 Set In Very Cold Temps Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 7147 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (Gas except LY6) Engine Cooling Fans (10 Series) 1 - Engine Cooling Fan - Left 2 - Engine Cooling Fan - Right 3 - Forward Lamp Harness Front of the Engine Compartment Components (Diesel) Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Page 10359 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Note Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Diagrams Safety Disconnect Impact Sensor: Diagrams Component Connector End Views High Voltage Circuit Impact Detection Sensor (HP2) Page 13338 Fuse Holder Electrical Center Identification Views Fuse Holder X1 (Chassis Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Auxiliary Battery Positive Harness) (Gas with TP2) Fuse Holder X2 (Battery Positive Harness) (Diesel/Gas with 9L4) Fuse Holder X2 (Engine Harness) (4.3L with 9L4) Page 10191 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 8898 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Locations Oil Pressure Sensor: Locations Powertrain Component Views Left Side of the Engine Components (LFA/HP2) 1 - Ignition Coil 1 2 - Evaporative Emissions (EVAP) Canister Purge Solenoid Valve 3 - Fuel Injector 1 4 - Ignition Coil 3 5 - Fuel Injector 3 6 - Ignition Coil 5 7 - Fuel Injector 5 8 - Ignition Coil 7 9 - Fuel Injector 7 10 - Engine Oil Pressure (EOP) Sensor 11 - Knock Sensor (KS) 1 Right Side of the Engine Components (LFA/HP2) Wheels/Tires - Module Programming For 20/22 Inch Wheels Tire Pressure Module: All Technical Service Bulletins Wheels/Tires - Module Programming For 20/22 Inch Wheels INFORMATION Bulletin No.: 09-03-10-008B Date: July 23, 2010 Subject: Installation and Programming for 20 Inch and 22 Inch Accessory Wheels (RPO RPP) Models: 2009-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe (1500 Series Only) 2009-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL (1500 Series Only) Supercede: This bulletin is being revised to include the 2011 model year. Please discard Corporate Bulletin Number 09-03-10-008A (Section 03 - Suspension). The purpose of this bulletin is to provide a summary of the steps required for the technician to install LPO dealer installed 20/22 inch accessory wheels on a full-size utility or pickup. These wheel options are identified with the RPO code RPP (this designates the 17" wheel and tire that will be removed by the dealer). The following RPO codes designate the 20 inch or 22 inch accessory wheel that will be installed by the dealer: VSA, VSB, VSC, VSF, VS3, VZJ, VZK, VS5, VS4, VSJ, VSK, VZH, VSN, VS8. Vehicles with option RPP always require the following installation steps: 1. Install new accessory tire/wheel assemblies to the vehicle. 2. Reprogram the control modules for the new tire/wheel size (steps 2.1, 2.2, and 2.3 must be completed in order). 1. Contact TCSC to set-up the calibration database for the new tire size. 2. For 2009 and 2010 models, reprogram the EBCM (Electronic Brake Control Module) - use Tech 2(R) pass-thru programming in the Service Programming System (SPS). 3. Reprogram the ECM (Engine Control Module) - use Tech 2 pass-thru programming in the Service Programming System (SPS). 3. Reset the tire type and pressure. 1. Use the Tech 2(R) to perform a module set up for the RCDLR Module. Go to "Tire Type/Pressure Selection". 2. Select correct tire type (P-metric) and select the new tire pressure based on the new tire placard included with the accessory wheels. 4. Learn the new tire pressure monitor (TPM) sensors to the vehicle. 5. Install the new tire placard included with the accessory wheels. 6. Set the inflation pressure of each tire to the new placard value. For additional information on this process, please refer to Corporate Bulletin 06-03-10-001G (SUV) or 06-03-10-011F (Pickup). Warranty Information Disclaimer Page 4544 Note DO NOT use excessively abrasive cleaning tools on the sealing surface. Hand sanding with wet 400 grit sandpaper or use of a hand scraper is recommended. 22. Clean the sealing surface of the 3 phase cable cover as necessary. 23. Position the 3 phase cable cover (2) onto the PIM distribution box ensuring the seal remains in place. 24. Tighten the 3 phase cable cover fasteners (1). Tighten the fasteners to 9 Nm (80 lb in) . 25. Connect the drive motor generator control module assembly connector (1). 26. Fill the power electronics cooling system and test for leaks at all serviced connections. Refer to Generator Control Module Cooling System Draining and Filling (See: Service and Repair/Procedures) . 27. Install the sight shield. Refer to Drive Motor Generator Control Module Sight Shield Replacement (See: Drive Motor Generator Control Module Sight Shield Replacement) . 28. Install the fender cross brace. Refer to Front Fender Rear Upper Brace Replacement (See: Body and Frame/Fender/Front Fender/Service and Repair) . 29. Perform the High Voltage Enabling procedure. Refer to High Voltage Enabling (See: Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Enabling) . 30. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair) . 31. For control module programming and setup procedures, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) . Page 6280 3. Connect the engine wiring harness electrical connector (7) to the HO2S. 4. Install the engine wiring harness electrical connector clip (6) to the fuel line clip. 5. Install the CPA retainer (4). 6. Install the front propeller shaft to the front differential, if equipped with 4WD. Refer to Front Propeller Shaft Replacement (See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement) . 7. Lower the vehicle. Page 11703 Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair) . 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair) . Note Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement) . Note If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Service and Repair Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) . 2. Remove the left front wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) . 3. Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair) . 4. Remove the lower outer bolt (1) from the washer container prior to lowering the vehicle. 5. Disconnect the washer pump hoses (1, 2) from the left side fender flange. Refer to Windshield Washer Hose Replacement (See: Windshield Washer Hose/Service and Repair) . Page 1888 1 - Turbocharger Vane Position Control Solenoid Valve 2 - Glow Plug Control Module (GPCM) 3 Fuel Temperature Sensor 4 - Intake Air Temperature (IAT) Sensor 2 Connector 5 - X128 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Generator - Auxiliary (K76/YF2) 8 - A/C Compressor Clutch (C67/CJ2) 9 - Engine Coolant Temperature (ECT) Sensor 10 - Camshaft Position (CMP) Sensor 11 - X127 12 - Generator 13 - Manifold Absolute Pressure (MAP) Sensor 14 - Intake Air Heater (IAH) 15 - Intake Air Temperature (IAT) Sensor 2 16 - Fuel Heater 17 - A/C Low Pressure Switch (C67/CJ2) Page 1535 Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Page 9844 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 8142 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools J-38125 Terminal Repair Kit Page 7032 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Fuse Block - Auxiliary Radiator Cooling Fan Motor Relay: Locations Fuse Block - Auxiliary Electrical Center Identification Views Fuse Block - Auxiliary (HP2) Label Page 10021 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Page 19422 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 6202 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) . Page 7484 bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through October 31, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through October 31, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2008-09 Chevrolet Tahoe or GMC Yukon; 2009 Cadillac Escalade, Chevrolet Silverado, or GMC Sierra vehicle, equipped a Two-Mode Hybrid Transmission may have a condition in which excessive pressure on the transmission clutch could cause a fracture. This may result in an improper transmission shift when shifting from third to fourth gear. It may also cause the engine to run at a higher RPM, reduce fuel economy, and illuminate the Service Engine Soon light. Your satisfaction with your Cadillac Escalade, Chevrolet Tahoe, or GMC Yukon is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will reprogram the transmission controller to reduce the clutch pressure and possibly replace the control solenoid valve. This service will be performed for you at no charge until October 31, 2011. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Rear of the Engine Compartment Component Views Air Flow Meter/Sensor: Locations Rear of the Engine Compartment Component Views Front of Vehicle/Engine Compartment Component Views Rear of the Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Windshield Washer Fluid Level Switch 7 - Windshield Washer Fluid Pump 8 - Air Cleaner Box Rear of the Engine Compartment Components (4.3L) Page 2912 Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics) . * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Note DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution) . The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. Page 20991 Page 6638 Fuel Injector 3 (Diesel) Page 7549 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 14717 For vehicles repaired under warranty, use the table. Disclaimer Page 2920 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2374 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 4. Disconnect the CH-48027-3 (4) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Tighten the fuel fill cap. Page 14063 Alignment: Description and Operation Toe Description Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 5782 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics) and follow the instruction to repair the wire. SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. Page 683 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 3636 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side Valve Rocker Arm Cover Replacement - Right Side Removal Procedure Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: * Identify how to disable high voltage. * Identify how to test for the presence of high voltage. * Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed. Failure to follow the procedures exactly as written may result in serious injury or death. 1. Disable the high voltage system. Refer to High Voltage Disabling (See: Hybrid Drive Systems/Battery System, Hybrid Drive/Testing and Inspection/Initial Inspection and Diagnostic Overview/High Voltage Disabling) . 2. Remove the intake manifold cover. Refer to Upper Intake Manifold Sight Shield Replacement (See: Intake Manifold/Service and Repair) . 3. Remove the generator control module 3 phase cable clip nut (1). 4. Remove the generator control module 3 phase cable clip from the engine bracket (2). 5. Reposition the generator control module 3 phase cables out of the way. Page 7091 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Page 12550 Disclaimer Page 6138 Camshaft Position (CMP) Sensor (4.8L/5.3L/6.0L/6.2L) Page 2698 Fuse Block - I/P X2 (except MEX) Page 18387 Disclaimer Page 9158 Transmission Speed Sensor: Diagrams Component Connector End Views Output Speed Sensor (OSS) (M99) Automatic Transmission Turbine Speed Sensor (MW7) Page 18882 ‹› If the test lamp does not illuminate, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminates between the B+ circuit terminal E and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Disconnect the X2 harness connector at the CCSM. 5. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. 6. If all circuits test normal, replace the CCSM. Driver Heated/Cool Seat Inoperative 1. Ignition OFF, disconnect the X1, X2, X3 harness connectors at the CCSM. 2. Connect a test lamp between the signal circuit terminal 14 X3 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. Note If the resistance is measured with the seat still warm or cool, the resistance values will vary. At 68°F, (20°C) the nominal resistance value is 1200 Ω ±5 percent . For warmer or cooler ambient temperatures, refer to the Temperature vs Resistance table below. The delta resistance values between the seat cushion and seat back temperature sensors should not be greater than 2000 Ω. 4. Ignition OFF, test for 300 Ω - 18 kΩ between the signal and low reference circuits listed below: * Seat cushion temperature sensor signal circuit terminal 7 X2 and low reference circuit terminal 8 X2. * Seat back temperature sensor signal circuit terminal 9 X2 and low reference circuit terminal 10 X2. ‹› If less than the specified range, test for a short between the signal and low reference circuits. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. ‹› If greater than the specified range, test the signal and low reference circuits for a short to voltage or an open/high resistance. If the circuits test normal, test or replace the appropriate seat cushion or seat back heat/cool seat ventilation blower. Note The test leads must be connected in the correct polarity, otherwise lower out of range values will appear. Use the Positive Lead for the COOL control circuit and the Negative Lead for the HEAT control circuit. If the resistance is measured with the seat still warm or cool, the resistance values will vary even if the system was powered up for just a few seconds. The TED must be allowed to stabilize to room temperature prior to a measurement. The conditions listed below will change the resistance to out of range values: * The test leads are incorrectly connected. * Air blowing across the TED. * Measuring the resistance at other than room temperature of 70°F (21°C). * Holding the TED portion of the heat/cool seat ventilation blower in your hand. Heated/Cooled Seats Inoperative-(Split For Indexing)-Part 2 Heated/Cooled Seats Inoperative In warmer or cooler climates where room temperature conditions of 70°F (21°C) may be unattainable, resistance values may read above the specified range. Use a heat gun or a blower to warm or cool the TED while measuring the resistance. The resistance values should slowly lower toward the specified range. 5. Test for 0.9 - 10.0 Ω between the control circuits listed below: * Seat cushion control circuit terminal G X1 and control circuit terminal H X1 * Seat back control circuit terminal J X1 and control circuit terminal K X1 Service and Repair Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure Note Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator from the MAF/IAT sensor. Refer to Air Cleaner Resonator Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair) . 2. Disconnect the engine wiring harness electrical connector (2) from the MAF/IAT sensor (1). Page 8854 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Page 18461 Memory Seat Module (MSM) X7 (AN3) Page 17516 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) . 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Page 7589 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center I/P (UQA with Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Accessory Power Outlet - I/P 2 11 Multifunction Switch Assembly - I/P 12 - Accessory Power Outlet - I/P 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch - Right (UK3) 15 - Steering Wheel Control Switch - Left (K34/KA9) 16 - Trailer Brake Control Switch (JL1) 17 - Headlamp and Panel Dimmer Switch 18 - Dimmer Control 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 Turn/Signal Multifunction Switch Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 5691 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 11680 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Wireless Communication Interface Antenna Replacement Antenna, Phone: Service and Repair Wireless Communication Interface Antenna Replacement Wireless Communication Interface Antenna Replacement Page 7888 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Note Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Page 3606 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 7791 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 6030 1 - Battery Current Sensor (except MEX) 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Rear of the Engine Compartment Components (TP2) A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 15090 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) Behind the I/P Components (CJ2)